Hach BioTector B7000i User manual

Catalog Number: 10-MAT-1052
BioTector B7000i Online TOC Analyzer
USER MANUAL
September 2015, Edition 1
BS4Ai 05.00a
Dairy
© Copyright BioTector 2015. All rights reserved. Printed by BioTector. Printed in the Republic of Ireland.

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Table of Contents
SECTION 1 SAFETY PRECAUTIONS.......................................................................... 5
1.1 INFORMATION AND SAFETY SIGNS USED IN THE MANUAL.......................................................5
1.2 PRECAUTIONARY LABELS ATTACHED TO THE INSTRUMENT.................................................... 6
1.3 CERTIFICATION MARKS ATTACHED TO THE INSTRUMENT.......................................................8
1.4 POTENTIAL SYSTEM SAFETY HAZARDS................................................................................9
1.4.1 Ozone and Toxicity...................................................................................................................... 10
1.4.2 First Aid Treatment...................................................................................................................... 10
1.5 GENERAL SAFETY PRECAUTIONS ...................................................................................... 11
1.5 PRÉCAUTIONS GÉNÉRALES DE SÉCURITÉ ........................................................................... 11
1.5.1 Electrical and Burn Precautions.................................................................................................. 12
1.5.1 Précautions relatives à l’électricité et aux brûlures ..................................................................... 12
1.5.2 Carrier Gas and Exhaust Gas Precautions................................................................................. 13
1.5.2 Précautions relatives au gaz porteur et d'échappement............................................................. 13
1.5.3 Chemical Precautions ................................................................................................................. 14
1.5.3 Précautions chimiques ................................................................................................................ 14
1.5.4 Sample Stream Precautions........................................................................................................ 15
1.5.4 Précautions relatives aux échantillons........................................................................................ 16
SECTION 2 OPERATOR’S MANUAL ......................................................................... 17
2.1 SOFTWARE SCREENS AND SOFTWARE MENU DIAGRAM............................................................ 17
2.1.1 Startup State................................................................................................................................ 19
2.1.2 System Status Messages............................................................................................................ 19
2.1.3 Analysis Data Screen.................................................................................................................. 20
2.1.4 Analysis Graph Screen................................................................................................................ 21
2.1.5 Reagent Status Screen ............................................................................................................... 21
2.1.6 Select Level Menu....................................................................................................................... 22
2.1.7 Enter Password Menu................................................................................................................. 22
2.2 OPERATION MENU............................................................................................................ 23
2.2.1 Start Stop..................................................................................................................................... 23
2.2.2 Reagents Setup........................................................................................................................... 25
2.2.2.1 Install New Reagents.........................................................................................................................25
2.2.2.2 Purge Reagents & Zero.....................................................................................................................26
2.2.3 System Range Data Screen........................................................................................................ 26
2.2.4 Manual Program Menu................................................................................................................ 27
2.2.5 Reaction Archive Screen............................................................................................................. 28
2.2.6 Fault Archive Menu ..................................................................................................................... 29
2.2.7 Time & Date Menu ...................................................................................................................... 29
2.2.8 Contact Information..................................................................................................................... 29
2.3 CALIBRATION MENU.......................................................................................................... 30
2.3.1 Zero Calibration........................................................................................................................... 30
2.3.2 Span Calibration.......................................................................................................................... 32
SECTION 3 TECHNICAL SPECIFICATIONS.............................................................. 35
SECTION 4 INTRODUCTION...................................................................................... 38
4.1 BIOTECTOR MAJOR COMPONENTS .................................................................................... 38
4.1.1 Analysis Enclosure...................................................................................................................... 38
4.1.2 Electronics Enclosure.................................................................................................................. 40
4.2 BIOTECTOR OPERATION ................................................................................................... 42
4.2.1 BioTector Oxidation Method........................................................................................................ 42
4.2.2 BioTector Sample Injection ......................................................................................................... 43
4.2.3 BioTector Oxygen Concentrator.................................................................................................. 45
4.2.4 BioTector Analysis Types............................................................................................................ 47
4.2.4.1 TIC & TOC Analysis...........................................................................................................................47
4.2.4.2 TC Analysis........................................................................................................................................47
4.2.4.3 VOC (POC) Analysis .........................................................................................................................48

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SECTION 5 INSTALLATION....................................................................................... 49
5.1 BASIC SYSTEM REQUIREMENTS ........................................................................................ 49
5.2 UNPACKING AND INSTALLATION......................................................................................... 50
5.2.1 Analyzer Dimensions and Mounting............................................................................................ 51
5.2.2 Wiring Power and Signal Terminals............................................................................................ 53
5.2.3 Wiring External Power Disconnection Switch ............................................................................. 55
5.2.4 System Fuse Specifications........................................................................................................ 56
5.3 AIR SUPPLY AND REAGENT CONNECTIONS......................................................................... 57
5.3.1 Air Supply Connection................................................................................................................. 58
5.3.2 Reagent Connections.................................................................................................................. 59
5.4 SAMPLE,DRAIN AND EXHAUST CONNECTIONS ................................................................... 61
5.4.1 Sample Inlet Tube Position ......................................................................................................... 61
5.4.2 Drain, Bypass and Exhaust Connections.................................................................................... 63
SECTION 6 REAGENTS AND CALIBRATION STANDARDS.................................... 64
6.1 REAGENTS....................................................................................................................... 64
6.2 CALIBRATION STANDARDS ................................................................................................ 65
SECTION 7 ANALYZER COMMISSIONING AND STARTUP .................................... 68
SECTION 8 MAINTENANCE MENU........................................................................... 73
8.1 DIAGNOSTICS MENU.................................................................................................... 74
8.1.1 Process Test................................................................................................................................ 75
8.1.1.1 Pressure Test ....................................................................................................................................75
8.1.1.2 Flow Test...........................................................................................................................................76
8.1.1.3 Ozone Test........................................................................................................................................77
8.1.1.4 Sample Pump Test............................................................................................................................79
8.1.1.5 pH Test..............................................................................................................................................80
8.1.1.6 Sample Valve Test.............................................................................................................................84
8.1.1.7 Base Wash Test ................................................................................................................................85
8.1.2 Simulate....................................................................................................................................... 86
8.1.3 Signal Simulate............................................................................................................................ 90
8.1.4 Data Output................................................................................................................................. 92
8.1.4.1 Send Reaction Archive ......................................................................................................................93
8.1.4.2 Send Fault Archive ............................................................................................................................96
8.1.4.3 Send Configuration............................................................................................................................96
8.1.4.4 Send All Data.....................................................................................................................................96
8.1.5 Input/Output Status ..................................................................................................................... 97
8.1.6 Oxygen Controller Status ............................................................................................................ 98
8.1.7 Service......................................................................................................................................... 99
8.2 COMMISSIONING MENU ............................................................................................ 100
8.2.1 Reaction Time ........................................................................................................................... 100
8.2.2 Sample Pump............................................................................................................................ 101
8.2.3 Stream Program........................................................................................................................ 102
8.2.4 COD/BOD/LPI/FLOW Program................................................................................................. 103
8.2.5 New Reagents Program............................................................................................................ 105
8.2.6 Reagents Monitor...................................................................................................................... 106
8.2.7 Autocal Program........................................................................................................................ 107
8.2.8 4-20mA Program....................................................................................................................... 107
8.2.9 Alarm Program .......................................................................................................................... 109
8.2.10 Data Program........................................................................................................................ 110
8.2.11 Information ............................................................................................................................ 110
8.3 SYSTEMCONFIGURATION MENU............................................................................. 111
8.3.1 Analysis Mode........................................................................................................................... 112
8.3.2 System Program........................................................................................................................ 113
8.3.3 Calibration Data......................................................................................................................... 118
8.3.4 Sequence Program ................................................................................................................... 118
8.3.4.1 Average Program.............................................................................................................................118
8.3.4.2 Cleaning Program............................................................................................................................119
8.3.4.3 Zero Program...................................................................................................................................122
8.3.4.4 Span Program..................................................................................................................................123
8.3.4.5 Reagents Purge...............................................................................................................................125
8.3.4.6 Pressure/Flow Test Program...........................................................................................................125

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8.3.5 Output Devices.......................................................................................................................... 127
8.3.6 Reaction Check......................................................................................................................... 130
8.3.7 Result Integration ...................................................................................................................... 131
8.3.8 Fault Setup................................................................................................................................ 131
8.3.9 Fault Status ............................................................................................................................... 133
8.3.10 CO2 Analyzer........................................................................................................................ 134
8.3.11 Cooler Program..................................................................................................................... 135
8.3.12 Ozone Destructor Program................................................................................................... 136
8.3.13 Software Update ................................................................................................................... 137
8.3.14 Password .............................................................................................................................. 138
8.3.15 Language .............................................................................................................................. 138
8.3.16 Hardware Configuration........................................................................................................ 138
SECTION 9 TROUBLESHOOTING OF SYSTEM FAULT, WARNING AND
NOTIFICATION EVENTS ................................................................................................ 139
9.1 BIOTECTOR FAULT EVENT EXPLANATION AND REMEDIAL ACTION...................................... 139
9.2 BIOTECTOR WARNING EVENT EXPLANATION AND REMEDIAL ACTION................................. 143
9.3 BIOTECTOR NOTIFICATION EVENT EXPLANATION AND REMEDIAL ACTION .......................... 150
SECTION 10 SERVICE AND MAINTENANCE ............................................................ 151
10.1 WEEKLY MAINTENANCE .................................................................................................. 151
10.2 SIX MONTH SERVICE ...................................................................................................... 152
SECTION 11 SYSTEM REPLACEMENT AND SPARE PARTS.................................. 157
SECTION 12 GENERAL INFORMATION .................................................................... 161
12.1 EC DECLARATION OF CONFORMITY................................................................................. 161
12.2 DECLARATION OF COMPLIANCE....................................................................................... 162
12.3 WARRANTY AND EXCLUSIONS ......................................................................................... 163
12.4 REGIONAL AND COUNTRY SPECIFIC DOCUMENTS............................................................. 164
SECTION 13 APPENDICES......................................................................................... 166
APPENDIX 1INSTRUCTIONS FOR CONNECTING PRINTER TO BIOTECTOR................................... 166
APPENDIX 2SETTING UP WINDOWS TO RECEIVE DATA FROM BIOTECTOR ................................ 167
APPENDIX 3GLOSSARY OF TERMS AND ABBREVIATIONS.......................................................... 168
APPENDIX 4CONTACT INFORMATION...................................................................................... 170

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Section 1 Safety Precautions
Please read this manual before unpacking, setting up, or operating the BioTector.
BioTector should only be used by qualified trained staff and for the purpose it is intended for. Do not use or
install this equipment in any way other than the methods specified in this manual. The procedures and
methods described in this manual are based on assuming the user have basic, fundamental background on
electronics, chemistry and analyzer equipment.
If the instructions in this manual are not followed, the operation and protection provided by the
equipment may be impaired.
1.1 Information and Safety Signs used in the Manual
When any supplementary information is required and if any hazards exist, the necessary information and
safety signs (Information, Caution, Warning and Danger) will be displayed for the corresponding section or
procedure in this manual.
Used to indicate supplementary information, to call attention to
recommendations, to simplify the operation and to guarantee the correct use
of the equipment.
Used when there is a danger of minor damage to the system if the user does
not follow precautions.
Used when there is a danger of minor injury or serious damage to the
system if the user does do not follow the precautions.
Used when failure to observe a safety precaution may result in serious injury
or death.
Caution
WARNING
DANGER

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1.2 Precautionary Labels Attached to the Instrument
The labels and tags attached to the instrument are summarized below. Please read all labels and tags
attached to the instrument. If not observed, personal injury or damage to the instrument could occur.
This symbol, when displayed on the instrument, indicates that the user
must gather the necessary operation and/or safety information given in the
instruction manual.
This symbol, when attached on an enclosure, indicates an existing risk of
electrical shock and/or electrocution. Only qualified personnel should open
such enclosures and work with hazardous voltages.
This symbol, when displayed on a component, identifies that the
component surface can be hot. When it is necessary to work with this
component, it should be handled with care.
This symbol, when noted on a product, illustrates the risk of chemical harm
due to its corrosive, acidic, caustic or solvent nature. Only qualified and
trained staff should handle such chemicals.
This symbol, when displayed on the instrument, indicates the presence of
devices sensitive to Electro-Static Discharge (ESD). Prior to any work with
such components, the individual should be grounded via an earth strap to
prevent any possible damage.
This symbol, when displayed on the product, indicates that protective eye
wear must be used during the maintenance or service of the equipment.
This symbol, when used on the product, identifies the location of the
protective earth (ground) connection.

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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.
Electrical equipment marked with this symbol may not be disposed of in
European domestic or public disposal systems after 12 August 2005. In
conformity with European local and national regulations (EU Directive
2002/96/EC), European electrical equipment users must now return old or
end-of life equipment to the manufacturer for disposal at no charge to the
user.
Note: For return for recycling, please contact the equipment producer or
supplier for instructions on how to return end-of life equipment, producer-
supplied electrical accessories, and all auxiliary items for proper disposal.
Return of products under warranty
Please contact our Service Team before returning a defective device (see Appendix 4 Contact Information
for address). Ship the cleaned device to the address you have been given. If the device has been in contact
with process fluids, it must be decontaminated/disinfected before shipment. In that case, please attach a
corresponding certificate, for the health and safety of our service personnel.
Disposal
Please observe the applicable local or national regulations concerning the disposal of “waste electrical and
electronic equipment”.

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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
for details.
Conforms to
ANSI/UL Std. 61010-1
Certified to
CAN/CSA Std. 61010-1
If these marks are displayed on the instrument, they indicate
that “This product has been tested to Safety Requirements
of Electrical Equipment for Measurements, Control and
Laboratory use; Part 1: General Requirements of ANSI/UL
61010-1 and CAN/CSA-C22.2 No 61010-1”. 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.

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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
Please read the instructions in this manual carefully before installing or starting the BioTector.
The manufacturer cannot accept liability for damages due to non-observance of this manual. Use of spare
parts not supplied by the manufacturer will invalidate the warranty. The manufacturer shall not be liable for
omissions or errors contained herein or for incidental or consequential damages in connection with the
furnishing, performance, or use of this material.
The information contained in this manual is subject to change without notice.
The information contained herein is protected by copyright. Reproduction, adaptation, or translation of any
part of this manual without prior written permission is prohibited, except as allowed under the copyright laws.
Product names mentioned herein are for identification purposes only and may be trademarks or registered
trademarks of their respective companies.
Where manuals are translated into several languages, the source language text is considered as the original.
Maintenance and operation should not be carried out unless personnel have been fully
trained in the operation of the BioTector.
Prior to working on the inside of the analyzer, the technician should be grounded via an
earth strap.
Caution

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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
Properties of Ozone (O3)
Molecule Weight
47.9982 g/g-mol
Boiling Point
-119 0.3 °C
Melting Point
-192.7 0.2 °C
Exposure to even low concentrations of ozone can be damaging to delicate nasal, bronchial and pulmonary
membrane. Symptoms of acute ozone toxification appear at a concentration of about 1 ppm by volume. The
type and severity of symptoms depend on the concentration and duration of exposure. In mild cases and in
the early phases of severe cases, symptoms will include one or more of the following:
Irritation or burning of the eyes, nose or throat
Lassitude
Frontal headache
Sensation of sub-sternal pressure
Constriction or oppression
Acid taste in mouth
Anorexia
In more severe cases, the symptoms may include dyspnoea, cough, choking sensation, tachycardia, vertigo,
lowering of blood pressure, severe cramping, chest pain, and generalized body pain. Pulmonary oedema may
develop with delayed onset, usually one or more hours after exposure.
Following severe acute ozone toxification, recovery is slow. In the few severe human cases reported, 10 -14
days of hospitalization were required. In these cases, minimal residual symptoms were present for as long as
9 months, but all cases eventually recovered completely.
The 1983 ACGIH has recommended a Threshold Limit Value (TLV) of 0.1 ppm (0.2 mg/m3) for ozone. The
safe level for short human exposure to concentrations of ozone in excess of 0.1 ppm (Threshold Limit Value)
is not known with certainty. The atmospheric concentration immediately hazardous to life is likewise not
known, but inhalation of 50 ppm for 30 minutes would probably be fatal. The odor threshold of ozone for a
normal person is 0.01 - 0.02 ppm by volume in air.
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.