wtw TresCon User manual

ba43121e03 01/2011
TresCon
Pges analyzer module
Operating manual

Pges
ba43121e03 01/2011
Target group This manual is intended for all persons who are familiar with the
installation, operation and maintenance of WTW analyzers.
Detailed information on the previous experience required and the
qualification of the user are given in the chapter, SAFETY, on page 2-1
in the TERMINAL volume of this manual.
Copyright ©Weilheim 2011, WTW GmbH
Reproduction in whole - or even in part - is prohibited without the
express written permission of WTW GmbH, Weilheim.
Printed in Germany.

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TresCon Pges - List of contents
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 How it functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.1 Main steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.2 Oxidative digestion and hydrolysis . . . . . . . . . . 1-4
1.2.3 Orthophosphate determination . . . . . . . . . . . . . 1-4
1.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3.2 Retrofitting TresCon Pges . . . . . . . . . . . . . . . . . 1-6
1.3.3 Inserting the pump tubes . . . . . . . . . . . . . . . . . 1-13
1.3.4 Connecting the permeate and consumables . . 1-14
1.3.5 Initial commissioning . . . . . . . . . . . . . . . . . . . . 1-18
1.4 Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.5 Instrument parameters . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Calibration (AutoCal) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.1 Manually starting an AutoCal calibration
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.2 Display of calibration data . . . . . . . . . . . . . . . . 2-10
2.3 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4 View/change the AutoCal parameters . . . . . . . . . . . . . 2-12
2.5 View/change the AutoClean parameters . . . . . . . . . . . 2-14
2.6 AutoKorr parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6.1 Switching AutoKorr on/off . . . . . . . . . . . . . . . . 2-16
2.6.2 Carrying out a manual correction . . . . . . . . . . 2-18
2.7 View/change the Display parameters . . . . . . . . . . . . . . 2-21
2.8 View/change the Attenuation parameters . . . . . . . . . . 2-23
2.9 Parameter, View/change interval program . . . . . . . . . . 2-25
2.10 Changing/viewing the measuring interval . . . . . . . . . . 2-28
2.11 View/change the Dilution parameters . . . . . . . . . . . . . 2-30
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Starting the AutoClean procedure . . . . . . . . . . . . . . . . . 3-3
3.2 Fill system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Replenish NaOH (cleaning solution) . . . . . . . . . . . . . . . 3-7
3.4 Replenish dist. H2O . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5 Replenish standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

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3.6 Replenish reagents A + B (C + D) . . . . . . . . . . . . . . . .3-13
3.7 Empty reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3.8 Empty system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3.9 Displace/replace pump tubings . . . . . . . . . . . . . . . . . . .3-19
3.9.1 Replace pump tubings . . . . . . . . . . . . . . . . . . .3-21
3.9.2 Displace pump tubings . . . . . . . . . . . . . . . . . .3-25
3.10 Test lamp /replace lamp . . . . . . . . . . . . . . . . . . . . . . . .3-29
3.10.1 Test lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3.10.2 Replace lamp . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3.11 Replacing the tubing system . . . . . . . . . . . . . . . . . . . . .3-34
3.12 Changing/viewing the service intervals . . . . . . . . . . . . .3-40
3.13 Switching AutoFlow on/off . . . . . . . . . . . . . . . . . . . . . .3-42
4 What to do if... . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.1 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.3 Service messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . .5-1
6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.1 Accessories and wear parts . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 Pressure sensors and messages . . . . . . . . . . . . . . . . . .6-2
6.3 RS commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6.4 Instrument states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
6.5 Preparing the reagents . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6.5.1 Preparing the reagent solution C . . . . . . . . . . . .6-9
6.5.2 Preparing the cleaning solution (NaOH) . . . . . .6-9
7 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

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1Overview
This operating manual has a modular structure, i.e. it contains a
separate operating manual for the individual components of the
multiparameter analyzer (see Fig. 1-1). This volume covers the
operation of the TresCon Pges analyzer module (highlighted in gray in
Fig. 1-1).
Structure of the
operating manual
Fig. 1-1 Structure of the operating manual (example)
Note
Please read chapter 2, SAFETY, in volume 1, TERMINAL, of this operating
manual before starting to work with the analyzer module.
Volume 2
TresCon
Pges
Operating
manual
Volume 3
TresCon
Module 2
Terminal
TresCon
Pges
Module 1
TresCon
Module 2
TresCon analyzer
Volume 1
TresCon
Terminal

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1.1 Structure
Principle diagram
Fig. 1-2 Schematic diagram
Equipment
Decomposition
reactor
Outlet
V6
P2A
P2C
P2B
P1C
P1B
P1A
V5
V7
V3
V1
V2
V4b V8b
V8a
V4a
Cleaning solution
(NaOH)
Deionized
water
Standard B Reagent A
(Peroxodisulfate)
Reagent B
(Sulphuric acid)
Reagent C
()Ascorbic acid
Reagent D
(Molybdate solution)
Sample
currentless path, filled
currentless path, open
currentless path, closed
Photometer
P6
P4
P5
P2
P3
P1
P1A: purple / orange / purple
P1B: orange / orange / orange
P1C: orange / orange / orange
P2A: blue / blue / blue
P2B: orange / green / orange
P2C: orange / green / orange
Pump tubings:
Components (number) Designation
Valves (9) V1, V2, ... V4a/b, V5, ... V8a/b
Pumps (2) P1A/B/C, P2A/B/C
Pressure sensors (6) P1 - P6
Temperature sensors (2) NTC and PT100
Heating (2) 32 W and 300 W
Ventilator (1)
Lamps (1)

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View of the Pges
analyzer module
Fig. 1-3 The TresCon Pges analyzer module
Control LED A light emitting diode located on the measuring block provides the
following information:
Control LED
Digestion
Photometer
Photometer
P1A/B/C
lamp
reactor
P2A/B/C
Pumps:
LED illuminates Meaning
red, continuous Malfunction of any type
green, continuous A service is being performed on the analyzer
module or a designation is being given to the
analyzer module (terminal software)
green, flashing System OK

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1.2 How it functions
1.2.1 Main steps
The total phosphorous content is determined by the TresCon Pges
analyzer module in two main steps:
zOxidative digestion of organic phosphorous compounds and
hydrolysis of tripolyphosphates.
zDetermination of the total orthophosphate PO43- with the aid of the
phosphorous molybdenum blue method (photometric process).
1.2.2 Oxidative digestion and hydrolysis
Digestion takes place in the left-hand section of the Pges analyzer
module. The sample is mixed with a peroxydisulfate solution and
sulfuric acid. The mixture is heated under pressure to a minimum
temperature of 120 °C. During this, essentially two processes take
place which create orthophosphate (PO43-) at the end:
zOxidation of organic phosphorous compounds and phosphorous
compounds with lower oxidation levels. Under the effect of the acid,
peroxydisulfate S2O82- is catalytically degraded. Reactive oxygen is
created. This oxidizes organic and inorganic compounds. At the
same time, the phosphorous bound in phosphoric compounds is
converted to orthophosphate.
zHydrolysis of tripolyphosphates. At the high temperature in the
digestion reactor and under the effect of the acid, tripolyphosphates
are converted into orthophosphate (acidic hydrolysis).
With biological phosphates (ATP, NAD, nucleic acids etc.), both
processes take place in combination: The organic part of the molecule
is subject to oxidative attack while the polyphosphate part is subject to
hydrolytic attack.
1.2.3 Orthophosphate determination
For the orthophosphate determination, the sample still combined with
sulfuric acid is pumped from the digestion reactor into the right-hand
section of the Pges analyzer module that is equipped with a process
photometer. The sample is mixed with a molybdate solution and an
ascorbic acid solution. The following steps then result:
zUnder the effect of the acid, the orthophosphate is transformed into
phosphorous molybdenum acid. This is created in the so-called β
modification, which is colorless. The molybdenum in it has the
valency +VI.
zThe phosphorous molybdenum acid is reduced by the ascorbic acid.

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At the same time, part of the molybdenum VI is converted to
molybdenum V. The compound that arises is colored blue
(phosphorous molybdenum blue).
zThe built-in process photometer determines the absorption of the
blue solution. The control unit of the analyzer module calculates the
original content of phosphorous in the sample from the absorption.
1.3 Commissioning
1.3.1 Scope of delivery
When the analyzer is delivered, it already has individual analyzer
modules integrated in it and is ready for operation.
The TresCon Pges module is available as a retrofit kit with the following
scope of delivery:
zP511: TresCon Pges analyzer module
zOperating manual to be added to the main folder
zCool box KB/P511
zReagents for 60 days
– R/P511: 1.5 L reagent A (oxidation reagent)
– R/P511: 1.5 L reagent B (hydrolysis reagent)
– R/P511: reagent C (reduction reagent),
container with ascorbic acid to fill with 0.5 L deionized water to
prepare a ready for use solution.
– R/P511: 0.5 L reagent D (color reagent)
– S/ BI - P211: 1.5 L standard B, measuring range I
– R/ A111: sodium hydroxide pellets and Na2EDTA for 10 L
cleaning solution
z1 x BEH/ T 10: empty 10 L container to prepare the cleaning solution
z1 x BEH/ T 1,5: empty 1.5 L container for cleaning solution
z1 x BEH/ T 1,5: empty 1.5 L container for standard A (H2O dist.)
z1 x screw cap for standard A, yellow
z1 x screw cap for standard B, orange
z1 x screw cap for cleaning solution, blue
z4 x screw cap for reagents A ... D, green
z1 x TC/ÜB 1: Simple overflow vessel
z4 x Wpack/P511, sets with spare tubes, altogether sufficient for a
typical yearly demand

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1.3.2 Retrofitting TresCon Pges
This section is only relevant if the TresCon Pges module was
purchased as a retrofit kit. Two free module slots must be available at
the basic instrument for the retrofitting.
Preparatory activities Installing TresCon Pges in an existing measuring system can require
some preparation:
zDisplacing the existing analyzer module to the right-hand mounting
slot (module 3, connection cable on the right side)
zSelection of the permeate supply:
Setting up a separate permeate supply (with its own catch location)
or connection to an existing permeate supply (catch location with
further analyzer modules)
Note
Read the INSTALLATION section in the TERMINAL volume of the operating
manual before starting the retrofit!

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Installing the analyzer
module
Fig. 1-4 Remove the left cover plate
1Switch off the TresCon at the power switch (on the mounting
stand).
2 Open the door of the TresCon.
3At the mounting slot, undo the screws (B) of the left dummy
plate (see Fig. 1-4) and remove the dummy plate.
Keep the fixing screws. They will be required in step 5!
TresCon
TresCon N0x-N
Ser.-Nr. 00110020
WTW82362 Weilheim Made in Germany
TresConNOx-N
Reinigungslösung
CleaningSolution
Ablauf
V2
Thermoblock
Probe
Sample
V1
HO dest.
HO dest.
2
2
blau
blue
blau
blue
rot
red
PumpschlauchStandard/Probe
blau/ blau / blau
PumpTube Standard/Sample
blue/ blue / blue
rot
red
P3
P1
10 fixing screws (B)

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Fig. 1-5 Removing the center cover plate
4Also undo the screws on the second, adjacent dummy plate
and remove the cover (see Fig. 1-5).
Keep the fixing screws.
TresCon
TresCon N0x-N
Ser.-Nr. 00110020
WTW82362 Weilheim Made in Germany
TresConNOx-N
Reinigungslösung
CleaningSolution
Ablauf
V2
Thermoblock
Probe
Sample
V1
HO dest.
HO dest.
2
2
blau
blue
blau
blue
rot
red
PumpschlauchStandard/Probe
blau/ blau / blau
PumpTube Standard/Sample
blue/ blue / blue
rot
red
P3
P1
10 fixing screws (B)

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Fig. 1-6 Attaching the TresCon Pges module
5Place the TresCon Pges module in the mounting frame and
screw it in place with the 20 screws (B) (see Fig. 1-6).
TresCon
AA
AB CD
TresCon Pges
Ser.-Nr. 00110010
WTW82362 Weilheim Made in Germany
Ser.-Nr. 00110010
WTW82362 Weilheim Made in Germany
AB
P1A: purpur / orange / purpur
P1B: orange / orange / orange
P1C: orange / orange / orange
P2A: blau / blau / blau
P2B: orange / grün / orange
P2C: orange / grün / orange
Reinigungslösung
(NaOH)
Cleaningsolution
(NaOH)
Entionisiertes
Wasser
Deionized
water
StandardB
StandardB
ReagenzA
(Peroxodisulfat)
ReagentA
(Peroxodisulfate)
ReagenzB
(Schwefelsäure)
ReagentB
(Sulphuricacid)
ReagenzC
()Ascorbinsäure
ReagentC
()Ascorbicacid
ReagenzD
(Molybdat-Lösung)
ReagentD
(Molybdatesolution)
Aufschluß-
reaktor
Decomposition
reactor
Ablauf/Outlet
V6
P2A
P2C
P2B
P1C
P1B
P1A
V5
V7
V3
V1
V2
V4b V8b
V8a
V4a
Probe
Sample
stromloserPfad gefüllt / currentless path, filled
stromlosoffen / currentless path, open
stromlosgeschlossen / currentless path, closed
Photometer
P6
P4
P5
P2
P3
P1
OP 510 TresCon Pges
20 fixing screws (B)

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Fig. 1-7 Opening the mounting frame
6Undo the screws (A) (see Fig. 1-7) and carefully tilt out the
mounting frame forwards.
TresCon
AA
AB CD
TresCon Pges
Ser.-Nr. 00110010
WTW82362 Weilheim Made in Germany
Ser.-Nr. 00110010
WTW82362 Weilheim Made in Germany
AB
P1A: purpur / orange / purpur
P1B: orange / orange / orange
P1C: orange / orange / orange
P2A: blau / blau / blau
P2B: orange / grün / orange
P2C: orange / grün / orange
Reinigungslösung
(NaOH)
Cleaningsolution
(NaOH)
Entionisiertes
Wasser
Deionized
water
StandardB
StandardB
ReagenzA
(Peroxodisulfat)
ReagentA
(Peroxodisulfate)
ReagenzB
(Schwefelsäure)
ReagentB
(Sulphuricacid)
ReagenzC
()Ascorbinsäure
ReagentC
()Ascorbicacid
ReagenzD
(Molybdat-Lösung)
ReagentD
(Molybdatesolution)
Aufschluß-
reaktor
Decomposition
reactor
Ablauf/Outlet
V6
P2A
P2C
P2B
P1C
P1B
P1A
V5
V7
V3
V1
V2
V4b V8b
V8a
V4a
Probe
Sample
stromloserPfad gefüllt / currentless path, filled
stromlosoffen / currentless path, open
stromlosgeschlossen / currentless path, closed
Photometer
P6
P4
P5
P2
P3
P1
OP 510 TresCon Pges

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Cable connection
Fig. 1-8 Assigning the internal numbers (example: Pges on the left)
Fig. 1-9 Plug connection on the back of TresCon Pges
7Connect the open socket of the TresCon Pges module with
one of the two open cable plugs that are located on the
matching slots behind the mounting frame. The second plug
remains unused. TresCon automatically assigns the correct
internal numbers to the installed modules (left-hand analyzer
module = 1; right-hand analyzer module = 2.)
Terminal
1 3
Internal number
Mounting slots
TresCon
2
12
TresCon Pges
Plug

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Connecting the outlet The outlet of TresCon Pges consists of an outlet tube and a ventilation
tube and is already prepared for connection in the TresCon enclosure.
Inside diameter (ID) of outlet tube: 10 mm
Inside diameter (ID) of ventilation tube: 3 mm
Fig. 1-10 Outlet adapter
8Connect the open end of the TresCon Pges outlet tube with the
outlet adapter in the bottom of the TresCon enclosure (see Fig.
1-10).
9Connect the open end of the ventilation tube to the outlet
adapter as well.
10 Carefully swing the mounting frame back into place.
11 Fix the mounting frame in place with the two screws (A) as
shown in Fig. 1-6.

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1.3.3 Inserting the pump tubes
The pump tubes were removed from the pump cassettes in the factory
in order to preserve them from damage during transport. Insert the
pump tubes at the pumps P1 and P2 as follows:
Fig. 1-11 Removing the pump cassette
Fig. 1-12 Inserting the tube in the pump cassette
1Swing out the pump cassette. To do so, open the gripping
lever. Subsequently, unlock the pump cassette by pressing on
the gripping lever and swing out the pump cassette, Fig. 1-11.
2Insert the pump tube in the pump cassette so that the second
section is on the suction side (Fig. 1-12).
3 Click the cassette into place in the peristaltic pump and close
the gripping lever.
2. Unlock
3. Tilt pump cassette
to the side
1. Open gripping lever
4. Remove pump
cassette
Clamping lever
Pump cassette
Pump direction
Section 1Section 2
Gripping lever:
Tighten
Loosen

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1.3.4 Connecting the permeate and consumables
Note
Most of the reagents and consumables are already prepared ready to
use. The reagent C and cleaning solution have to be freshly prepared
(see section 6.5).
This section is about the connection of the permeate and reagent
supply.
Warning
Only trained personnel is allowed to work on the analyzing section.
Always take safety precautions when handling chemicals and comply
with the relevant regulations. This applies especially to the warning
instructions on the chemical containers and in the safety data sheets.
Always use the proper safety equipment!
Connecting the
permeate supply
Fig. 1-13 Connecting the permeate feed
Wear protective
goggles
Wear protective
gloves
Wear protective
clothing
1Feed the permeate tube of the TresCon Pges module (black,
ID = 1.5 mm) out through the hole drilled in the base of the
housing to the outside.
2 Stick the permeate tubing into the overflow vessel provided.
To the overflow vessel
Drilled hole Enclosure base

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Note
If the TresCon Pges module is to be connected to an already installed
overflow vessel (determination of several parameters at a single
sampling location), an overflow vessel with 3 permeate nozzles must
be used at this position. If this is not the case, replace the overflow
vessel.
If the TresCon Pges module is to measure a new sampling location, a
further overflow vessel must be mounted.
Connecting the supply
of consumables
Fig. 1-14 Connecting the supply of consumables
Color coding
of the consumables
The tubes of the consumables are nontransparent and color coded:
3Feed the tubes for the consumables (color coding see below)
out through the holes drilled in the base of the housing to the
outside.
blue
yellow
orange
green
green
green
green
blue Cleaning solution (NaOH solution)
yellow Standard A (dist. H2O)
orange Standard B
green Reagent A (peroxydisulfate solution)
green Reagent B (diluted sulfuric acid)
green Reagent C (ascorbic acid solution)
green Reagent D (molybdate solution)

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Fig. 1-15 Color coding
Connecting the
cleaning solution
Cleaning solution (NaOH) causes severe corrosion
Do not allow this substance to get into the hands of children. Wear
suitable protective gloves and goggles/face mask when working with
this substance.
If this substance gets into the eyes, rinse thoroughly with water and
consult a doctor.
Connecting standard A
(dist. H2O)
Connecting standard B
Vent
Color Coding
4Briefly shake the closed container with cleaning solution
(NaOH).
5 Place a container of cleaning solution on the tray.
6Connect the (blue) screw cap with the (blue) suction hose (see
Fig. 1-15). When doing so make sure the ventilation hole in the
screw cap is free and dry.
7Place a full container of standard A (dist. H2O) on the tray.
8 Connect the (yellow) screw cap with the (yellow) suction hose.
9Place a full container of standard B on the tray.
10 Connect the (orange) screw cap with the (orange) suction
hose.