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Scrubber K-415
Operation Manual
11593505 en
Document History
Index
A
B
Date Author Changes
23/MAR/2012 NAGG Initial version
20/FEB/2014 OTTD Declaration of conformity, noise level, degree of protection deleted, note concerning access to mains plug added, text in improper use added, pictures updated
Imprint
Product Identification:
Operation Manual (Original), Scrubber K-415
11593505 en
Publication date:
06.2015, Version B
BÜCHI Labortechnik AG
Meierseggstrasse 40
Postfach
CH-9230 Flawil 1
E-Mail: [email protected]
BUCHI reserves the right to make changes to the manual as deemed necessary in the light of experience; especially in respect to structure, illustrations and technical detail.
This manual is copyright. Information from it may not be reproduced, distributed, or used for competitive purposes, nor made available to third parties. The manufacture of any component with the aid of this manual without prior written agreement is also prohibited.
Table of contents
Table of contents
1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 User qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Safety warnings and safety signs used in this manual . . . . . . . . . . . . . . . . . 10
2.5 Product safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.1 General hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.2 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.3 Built-in safety elements and measures . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 General safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 DuoScrub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 TripleScrub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.3 TripleScrub ECO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.4 QuadScrub ECO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.5 Standard accessories for all scrubber models . . . . . . . . . . . . . . . . . . . . . 17
3.1.6 Optional upgrade sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Technical data overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Materials and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Recommended consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Information on type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Functional principle of the Scrubber . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Scrubber capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Installation site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.1 Anti-seismic-tie-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 General installation procedure for all Scrubber models . . . . . . . . . . . . . . . . 26
5.3 Equipping the Scrubber with the condenser unit . . . . . . . . . . . . . . . . . . . 28
Read this manual carefully before installing and running your system and note the safety precautions in chapter 2 in particular. Store the manual in the immediate vicinity of the instrument, so that it can be consulted at any time.
No technical modifications may be made to the instrument without the prior written agreement of
BUCHI. Unauthorized modifications may affect the system safety or result in accidents.
This manual is copyright. Information from it may not be reproduced, distributed, or used for competitive purposes, nor made available to third parties. The manufacture of any component with the aid of this manual without prior written agreement is also prohibited.
The English manual is the original language version and serves as basis for all translations into other languages. Other language versions can be downloaded at www.buchi.com.
2 K-415 Operation Manual, Version B
Table of contents
5.4 Installing the Reaction vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5 Receiving vessel with outlet - Total Kjeldahl Nitrogen set (optional) . . . . . . . . . . 30
5.6 Connecting the cooling water control (ECO-versions only). . . . . . . . . . . . . . . 31
5.7 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7.1 Hose connections of the DuoScrub . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7.2 Hose connections for the TripleScrub . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.7.3 Hose connections for the TripleScrub ECO . . . . . . . . . . . . . . . . . . . . . . . 34
5.7.4 Hose connections for the QuadScrub ECO . . . . . . . . . . . . . . . . . . . . . . . 35
5.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.9 Preparing washing solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.9.1 Washing solutions for acidic vapors and gases . . . . . . . . . . . . . . . . . . . . 37
5.9.2 Washing solutions for alkaline vapors and gases . . . . . . . . . . . . . . . . . . . 37
5.10 Filling up the prepared washing solution . . . . . . . . . . . . . . . . . . . . . . . . 38
5.11 Preparation of the adsorption vessel. . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.12 Filling the reaction stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1 Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Glass parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3 Hoses / hose connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4 Sealing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.1 Cleaning the gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.2 Replacing the seals / GL 14 connector . . . . . . . . . . . . . . . . . . . . . . . . 44
7.5 Washing insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.6 Washing solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.7 Active charcoal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.8 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.9 Hose cooling control / condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.10 Hose water control feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.11 Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.12 Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.13 Functional test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.14 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Malfunctions and their remedy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9 Shutdown, storage, transport and disposal . . . . . . . . . . . . . . . . . . . . . . . . 51
9.1 Storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.1 Spare parts on the exploded instrument view . . . . . . . . . . . . . . . . . . . . . 53
10.2 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11 Declarations and requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.1 FCC requirements (for USA and Canada) . . . . . . . . . . . . . . . . . . . . . . . 57
11.2 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3 K-415 Operation Manual, Version B
1 About this manual
4 K-415 Operation Manual, Version B
1 About this manual
1 About this manual
This manual describes the Scrubber and provides all information required for its safe operation and to maintain it in good working order.
It is addressed to laboratory personnel in particular.
NOTE
The symbols pertaining to safety (WARNINGS and ATTENTIONS) are explained in chapter 2.
1 .1 Reference documents
For information on the digestion instrument, please refer to the corresponding manuals available in
English, German, French, Italian and Spanish
• Digest System K-437, Operation Manual numbers 96760 - 96764
• Digest Automat K-438/432, Operation Manual numbers 96765 - 96769
• SpeedDigester K-425/K-436, Operation Manual numbers 11593346 - 15593350
• SpeedDigester K-439, Operation Manual numbers 15593351 - 15593355
• WetDigester B-440, Operation Manual numbers 096790 - 096794
• KjelDigester K-446/K-449, Operation Manual numbers 11593546 - 11593552, 11593643
1 .2 Abbreviations
CR: Chloroprene Rubber
EPDM : Ethylene Propylene Dimonomer
FEP: Fluorinated Ethylene Propylene
FPM: Fluoroelastomer pa: per analysis
PA : Polyamides
PMMA : Polymethylmethacrylate
POM : Polyoxymethylene
PP : Polypropylene
PPS : Polyphenylenesulfide
PTFE : Polytetrafluoroethylene
PUR : Polyurethanes
P+G: Plastic & Glass
PA12: Polyamide 12
5 K-415 Operation Manual, Version B
2 Safety
6 K-415 Operation Manual, Version B
2 Safety
2 Safety
This chapter points out the safety concept of the instrument and contains general rules of behavior and warnings from hazards concerning the use of the product.
The safety of users and personnel can only be ensured if these safety instructions and the safetyrelated warnings in the individual chapters are strictly observed and followed. Therefore, the manual must always be available to all persons performing the tasks described herein.
2 .1 User qualification
The instrument may only be used by laboratory personnel and other persons who on account of training or professional experience have an overview of the dangers which can develop when operating the instrument.
Personnel without this training or persons who are currently being trained require careful instruction.
The present Operation Manual serves as the basis for this.
2 .2 Proper use
The instrument has been designed and built for laboratories. It serves for the neutralization and adsorption of gases that arise during chemical reactions and syntheses.
Only gases with known chemical composition may be drawn off.
2 .3 Improper use
Applications not mentioned above are improper. Also, applications, which do not comply with the technical data, are considered improper. In particular no gases with unknown chemical composition may be drawn off.
If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
The operator bears the sole risk for any damages caused by such improper use.
The following uses are expressly forbidden:
• Use of the instrument in rooms which require ex-protected instruments.
• Use on samples, which can explode or inflame (example: explosives, etc.) due to shock, friction, heat or spark formation.
• Use in overpressure situations.
• Drawing off liquids.
• Drawing off solvents.
• Drawing off vapors of organic solvents.
• Use for cleaning of room air.
7 K-415 Operation Manual, Version B
2 Safety
2 .4 Safety warnings and safety signs used in this manual
DANGER, WARNING, CAUTION and NOTICE are standardized signal words for identifying levels of hazard seriousness of risks related to personal injury and property damage. All signal words, which are related to personal injury are accompanied by the general safety sign.
For your safety it is important to read and fully understand the table below with the different signal words and their definitions!
Sign Signal word Definition
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
CAUTION
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.
no NOTICE
Indicates possible property damage, but no practices related to personal injury.
Risk level
★★★★
★★★☆
★★☆☆
★☆☆☆
(property damage only)
Supplementary safety information symbols may be placed in a rectangular panel on the left to the signal word and the supplementary text (see example below).
Space for supplementary safety information symbols.
!
SIGNAL WORD
Supplementary text, describing the kind and level of hazard / risk seriousness.
• List of measures to avoid the herein described, hazard or hazardous situation.
• ...
• ...
Table of supplementary safety information symbols
The reference list below incorporates all safety information symbols used in this manual and their meaning.
Symbol Meaning
General warning
Electrical hazard
Harmful to life-forms
Inhalation of substances
8 K-415 Operation Manual, Version B
2 Safety
Symbol Meaning
Heavy weight, avoid overexertion
Chemical burns by corrosives
Fragile components
Explosive gases, explosive environment
Device damage
Wear laboratory coat
Wear protective goggles
Wear protective gloves
Additional user information
Paragraphs starting with NOTE transport helpful information for working with the device / software or its supplementaries. NOTEs are not related to any kind of hazard or damage (see following example).
NOTE
Useful tips for the easy operation of the instrument / software.
2 .5 Product safety
The Scrubber K-415 has been designed and built in accordance with current state-of-the-art technology, at the time of development. Safety warnings in this manual (as described in section 2.4) serve to make the user alert to and avoid hazardous situations emanating from residual dangers by giving appropriate counter measures.
However, risks to users, property and the environment can arise when the instrument is damaged, used carelessly or improperly.
9 K-415 Operation Manual, Version B
2 Safety
2 .5 .1 General hazards
The following safety messages show hazards of general kind which may occur when handling the instrument. The user shall observe all listed counter measures in order to achieve and maintain the lowest possible level of hazard.
Additional warning messages can be found whenever actions and situations described in this manual are related to situational hazards.
!
DANGER
Death or serious injuries by use in explosive environments.
• Do not store or operate the instrument in explosive environments
• Remove all sources of flammable vapors
• Do not store chemicals in the vicinity of the device
!
CAUTION
Risk of minor or moderate cuts by sharp edges.
• Do not touch defective or broken glassware with bare hands
• Do not touch thin metal edges
NOTICE
Risk of instrument damage by liquids or mechanical shocks.
• Do not spill liquids over the instrument or its components
• Do not drop the instrument or its components
• Keep external vibrations away from the instrument
2 .5 .2 Personal protective equipment
Always wear personal protective equipment such as protective eye goggles, protective clothing and gloves. The personal protective equipment must meet all requirements of all data sheets for the chemicals used. These instructions are an important part of the Scrubber K-415 and must be made available at all times to the operating personnel at the place where the equipment is deployed. This also applies to additional language versions of these instructions, which can be reordered separately.
10 K-415 Operation Manual, Version B
2 Safety
!
WARNING
Serious chemical burns by corrosives.
• Observe all data sheets of the used chemicals
• Handle corrosives in well ventilated environments only
• Always wear protective goggles
• Always wear protective gloves
• Always wear protective clothes
• Do not use damaged glassware
2 .5 .3 Built-in safety elements and measures
Neutralization vessel P+G coated
The protective P+G coating of the neutralization vessel protects operators from risks, caused by parts of broken glass.
2 .6 General safety rules
Responsibility of the operator
The head of the laboratory is responsible for training his/her personnel.
The operator shall inform the manufacturer without delay of any safety-related incidents which might occur during operation of the instrument or its accessories. Legal regulations, such as local, state and federal laws applying to the instrument or its accessories must be strictly followed.
Duty of maintenance and care
The operator is responsible for the proper condition of instrument. This includes maintenance, service and repair jobs that are performed and on schedule by authorized personnel only.
Spare parts to be used
Use only genuine consumables and spare parts for maintenance to assure good system performance, reliability and safety. Any modifications of spare parts or assemblies are only allowed with the prior written permission of the manufacturer.
Modifications
Modifications to the instrument are only permitted after prior consultation and with the written approval of the manufacturer. Modifications and upgrades shall only be carried out by an authorized BUCHI technical engineer. The manufacturer will decline any claim resulting from unauthorized modifications.
11 K-415 Operation Manual, Version B
3 Technical data
12 K-415 Operation Manual, Version B
3 Technical data
3 Technical data
This chapter introduces the reader to the instrument specifications. It contains the scope of delivery, technical data, requirements and performance data.
3 .1 Scope of delivery
Check the scope of delivery according to the order number.
NOTE
For detailed information on the listed products, see www.buchi.com or contact your local dealer.
3 .1 .1 DuoScrub
Table 3-1: DuoScrub K-415
Product
230 V / 50/60 Hz
120 V / 50/60 Hz
100 V / 50/60 Hz
Order number
114152320
114151220
114151020
3 .1 .2 TripleScrub
Table 3-2: TripleScrub K-415
Product
230 V / 50/60 Hz
120 V / 50/60 Hz
100 V / 50/60 Hz
Standard accessories
Silicone hose 6/9 3 m
Order number
114152330
114151230
114151030
048355
13 K-415 Operation Manual, Version B
3 .1 .3 TripleScrub ECO
3 .1 .4 QuadScrub ECO
3 Technical data
Table 3-3: TripleScrub ECO K-415
Product
230 V / 50/60 Hz
120 V / 50/60 Hz
100 V / 50/60 Hz
Standard accessories
Hose for water control
Adapter with sieve for tap
Multi-tool
Silicone hose 6/9 3 m
Connection cable to digester
Order number
114152331
114151231
114151031
11057146
11058398
11058474
048355
030973
Table 3-4: QuadScrub ECO K-415
Product
230 V / 50/60 Hz
120 V / 50/60 Hz
100 V / 50/60 Hz
Standard accessories
Hose for water control
Adapter with sieve for tap
Multi-tool
Silicone hose 6/9 3 m
Connection cable to digester
Order number
114152341
114151241
114151041
11057146
11058398
11058474
048355
030973
14 K-415 Operation Manual, Version B
3 Technical data
3 .1 .5 Standard accessories for all scrubber models
3 .1 .6 Optional upgrade sets
Table 3-5: Standard accessories
Product
1 power cable
Type CH
Type Schuko / Japan
Type GB
Type USA
Type AUS
Operation Manual:
English
German
French
Italian
Spanish
Chinese
Japanese
Order number
010010
010016
017835
033763
017836
11593505
11593506
11593507
11593508
11593509
11593510
11593511
Table 3-6: Optional upgrade sets
Product
Condensation step
Reaction step
TKN set
Cooling water valve
Tray for adsorption storage
Connection cable to digester
IQ/OQ Scrubber K-415
Repeating OQ Scrubber K-415
Order number
11058460
11058461
11057333
11058462
11057332
030973
11058568
11058569
15 K-415 Operation Manual, Version B
3 Technical data
3 .2 Technical data overview
Table 3-7: Technical data
Scrubber Unit K-415
Dimensions (W x H x D)
(completely equipped instrument)
Weight
DuoScrub
TripleScrub
TripleScrub ECO
QuadScrub ECO
DuoScrub
TripleScrub
TripleScrub ECO
QuadScrub ECO
Power system voltage / frequency /consumption / fuse 230 V ± 10 % / 50/60 Hz
120 V ± 10 % / 50/60 Hz
100 V ± 10 % / 50/60 Hz
Installation site For indoor use only
Temperature + 5 °C to + 40 °C
Altitude up to 2000 m above sea level
248 x 412 x 526 mm
347 x 417 x 526 mm
347 x 417 x 543 mm
347 x 450 x 543 mm
10.1 kg
11.2 kg
12.3 kg
12.9 kg
140 W T1A L 250 V
140 W T2A L 250 V
140 W T2A L 250 V
Humidity
Pump suction capacity (max.)
System suction capacity
Overvoltage category
Pollution degree
Noise level maximum relative humidity 80 % for temperatures up to 31 °C, decreasing linearly to 50 % relative humidity at 40 °C
32 L/min (air) adjustable approximately between 50 and 400 mbar below atomspheric pressure
II
2
< 70 dB
3 .3 Materials and Approvals
Table 3-8: Materials and Approvals
Component
Housing
Minor hardware
Lip gasket acid- / base-resistant
Gasket
Cover of neutralization vessel
Glass parts
Pump
Hoses
Cooling water control
Water hose (black)
Water hode (white)
Approvals
Material designation
PUR
PP, PA, POM
FPM, EPDM
PTFE, CR
PMMA
Borosilicate 3.3, P+G plastic coated glass
PPS, CR, FPM
CR, FEP brass, FKM (sealing)
Polychloroprene Rubber brass, PA12
CE, CSA
16 K-415 Operation Manual, Version B
3 Technical data
3 .4 Recommended consumables
Table 3-9: Active charcoal for adsorption vessel
Product
Fluka, granules impregnated with potassium hydroxide for the chemisorption of acid vapors
Fluka, purum p.a. 4 - 8 mm
Merck, granulated
Table 3-10: Glasswool for adsorption vessel
Product
Glass wool
Table 3-11: Color indicator for washing solution
Product
Bromothymol blue, Merck
3 .5 Information on type plate
Order number
Fluka 29238
Fluka 05110
Merck 102518
Order number
033701
Order number
Merck 3026
17 a Instrument type code b Serial number c Supply voltage range / type d Frequency of supply voltage e Nominal power rating f Year of manufacture
K-415 Operation Manual, Version B
4 Description of function
18 K-415 Operation Manual, Version B
4 Description of function
4 Description of function
This chapter explains the basic principle of the instrument, shows how it is structured and gives a functional description of the assemblies.
The pump draws off the gases and vapors produced in chemical reactions via a condenser providing a receiving vessel underneath. The suction performance of the pump can be regulated via a bypass valve on the rearside of the instrument.
The condensation stage is used as a preliminary extractor for vapors, water steam (to prevent warming or an increase in volume of the washing solution) and for the liquids carried along with them, thus extending the service life of the neutraliza tion stage.
The acid or alkaline gases are washed and neutralized in the neutralization stage.
The next stage, the adsorption stage, holds back most of the undesired particles by means of granules of activated charcoal or a universal adsorption granulate. It also enables the aerosols to recondensate.
In the reaction stage that follows specific redox reactions are accomplished.
The used air is directly lead into an exhaust or into the open air through a silencer. The ECO -versions of the K-415 are equipped with a cooling water control unit that allows an automatic start and stop of the cooling water flow, triggered by the digester (or by the on/off switch of the K-415).
4 .1 Functional principle of the Scrubber
1
2
3
4
5
6 a Receiving vessel b Condenser c Reaction tubelet (Reaction stage)
Fig. 4.1: Overview over the Scrubber
19 d Adsorption vessel e Neutralization vessel f Tray for adsorption vessel and tube connector
K-415 Operation Manual, Version B
4 Description of function a Fume inlet into condenser b Condenser c Receiving vessel d Cooling water inlet of condenser e Cooling water outlet of condenser
Fig. 4.2: Functional principle of the Scrubber f Fume outlet of condenser g Neutralization vessel with washing solution h Adsorption vessel (filled with activated charcoal) i Reaction stage j Fume exhaust pump
Condensation stage
• Condensation of vapors
• Condensation of water steam (prevention of warming or an increase in volume of the washing solution)
• Condensation of the liquids carried along
Neutralization stage
• Neutralization of acid or alkaline gases
Adsorption stage
• Specific adsorptions and retention of particles (using granules of activated charcoal or a universal adsorption granulate)
• Recondensation of aerosols
Reaction stage
• Specific reactions (e.g., redox reactions)
20 K-415 Operation Manual, Version B
4 Description of function
4 .2 Scrubber capacity
The suction capacity of the Scrubber K-415 is designed for digestion units with a maximum of 20 sample tubes.
Connection examples:
• Connection of up to two SpeedDigesters K-425 (6 places each)
• Connection of one SpeedDigester K-436 / K-439 (12 places)
• Connection of one WetDigester B-440
• Connection of one KjelDigester K-446 / K-449 (20 places)
21 K-415 Operation Manual, Version B
5 Putting into operation
22 K-415 Operation Manual, Version B
5 Putting into operation
5 Putting into operation
This chapter describes how the instrument is installed and gives instructions on initial startup.
NOTE
Inspect the instrument for damages during unpacking. If necessary, prepare a status report immediately to inform the postal company, railway company or transportation company.
5 .1 Installation site
!
DANGER
Death or serious injuries by use in explosive environments.
• Do not store or operate the instrument in explosive environments.
• Remove all sources of flammable vapors.
• Do not store chemicals in the vicinity of the device.
!
CAUTION
Risk of minor or moderate injury by heavy weight of the instrument.
• Lift the instrument carefully and avoid over exertion.
• Do not drop the instrument or its transport box.
• Place the instrument on a stable, even and vibration-free surface.
• Keep limbs out of crushing zone.
!
WARNING
Serious chemical burns by corrosives.
• The instrument may only be operated within a fume hood.
• Handle corrosives in well ventilated environments only.
• Always wear protective goggles.
• Always wear protective gloves.
• Always wear protective clothes.
• Do not use damaged glassware.
NOTE
Place the Scrubber K-415 on the left side of a digestion unit (e.g. SpeedDigester, Digest System
K-437 or Digest Automat K-438/K-432). The Scrubber ventilation is located on the left side. In case the Scrubber is placed on the right side of another unit, cool air will hit the digestion sample and cool it down, so that no digestion can take place.
23 K-415 Operation Manual, Version B
5 Putting into operation
5 .1 .1 Anti-seismic-tie-down
For the use in earthquake-susceptible regions, the instrument can be equipped and secured with the anti-seismic-tie-down, contained in the standard delivery of the instrument.
The fixing device can be attached to the instrument from the bottom side of the instrument, close to the housing foot on the right rear side of the instrument.
• Slide the fixing bracket a into the provided groove b and fix it with the provided screw c .
• The instument can now be tied to the setup.
Fig. 5.1: Fixing the anti-seismic-tie-down
5 .2 General installation procedure for all Scrubber models
To commission the Scrubber K-415, proceed as follows:
• Make sure that the silencer ( a in figure 5.2) is filled with polyester fibres and install it:
1
Fig. 5.2: The silencer on the rear side of the instrument
• Check the glass for flaws and cracks.
• Check the seals and gaskets (embrittlement, scratches). If they are not OK, take them out and replace them (see also chapter 7).
• Carefully insert the glass parts. Otherwise there is a risk of damaging the glassware.
24 K-415 Operation Manual, Version B
5 Putting into operation
• Attach the tray for adsorption storage (optional available for DuoScrub) to the housing: Slide the tray a from the side into the groove in the housing b and fix it by tightening the screw c . After the tray has been attached to the housing of the scrubber, the adsorption vessel and the inlet tubing of the neutralization vessel can be stored in the tray, while the neutralization vessel is taken away from the instrument.
Fig. 5.3: Fixing the tray for adsorption storage
Fig. 5.4: Swiveling adsorption vessel and tubing to the tray
25 K-415 Operation Manual, Version B
5 Putting into operation
5 .3 Equipping the Scrubber with the condenser unit
To prepare a Scrubber model for operation with a condenser, proceed as follows:
• Unless the carrier-plate a for the condenser is not yet installed, slide it into the housing from the side and fix it with the two screws from below. The groove b must point away from the opening in the housing (see figure 5.5).
Fig. 5.5: Fixing the carrier plate
• Carefully slide the condenser from top into the opening in the housing and fix it on the carrier plate a with the rubber strap c . The rubber strap has to be passed through the groove on the backside of the carrier plate to prevent it from sliding up or down and to guarantee a tight positioning of the condenser (see arrow in figure 5.6). Make sure the connections of the condenser are pointing backward.
• The receiving vessel d can be attached from below and secured with the catchpot clip e .
Fig. 5.6: Fixing the condenser with the rubber strap
For the determination of the total Kjeldahl nitrogen (TKN) the optional TKN set can be used as an alter-
26 K-415 Operation Manual, Version B
native to the receiving vessel. For details please refer to chapter 5.5.
The connections of the condenser can be seen from the following schema: a Cooling water outlet b Connection to neutralization stage c Fume inlet (connection to emission source / digester) d Cooling water inlet
3 2 1
4
5 Putting into operation
Fig. 5.7: Connections of the condenser
5 .4 Installing the Reaction vessel
• Screw the screw cap c together with the gasket ring b loosely onto the reaction vessel a
.
• Insert the introduction tube assembly d
. Tighten the screw cap c
.
• Insert the mounted reaction vessel a from the side to the housing and place it in the groove i on the bottom of the housing (the introduction tube assembly d
has to protrude from the round opening on top of the housing j
).
• Attach the provided tubing g and
h using the provided screw caps f and gaskets e
(GL 14).
(See also chapter 5.7.4)
• (Dismount in the reversed order.)
7
6
5 6 8
4 10
5
4
3
2
1
9
1
Fig. 5.8 Installing the Reaction vessel
27 K-415 Operation Manual, Version B
5 Putting into operation
5 .5 Receiving vessel with outlet - Total Kjeldahl Nitrogen set (optional)
A receiving vessel with outlet a is optionally available. It serves for the digestion of samples with a large water content. Using the drain cock b it is possible to drain the collected volume of liquid during operation.
To install the optional TKN-set, proceed as follows:
• Attach the receiving vessel a with outlet to the condenser from below and secure it with the catchpot clip c .
• Attach the provided hose to the outlet of the cock and secure it with a hose clamp. Connect the other end of the hose to an appropriate collection tank or sink.
Fig. 5.9 Connecting the TKN set
NOTE
During manual operation of the K-415 the cock of the TKN receiving vessel has to be kept closed - otherwise the suction performance of the K-415 may not be sufficient to draw off all fumes produced by the digester. The cock shall only be opened for a very short time while the receiving vessel is discharged.
Manual operation:
1. Reduce the suction performance to a minimum.
2. Open the cock b of the receiving vessel.
3. Wait until the receiving vessel is completely emptied, then close the cock again.
4. Set the suction performance back to the previously used level .
Automatic operation:
1. Place an additional bigger vessel with sufficient capacity to the floor.
2. Connect the tube from the TKN set to this vessel.
3. Tighten the connection between the tube and the vessel (otherwise the suction capacity of the scrubber will go down and will no longer be sufficient to draw off all fumes produced by the digester).
4. The cock b of the receiving vessel a can now be left open permanently.
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5 Putting into operation
5 .6 Connecting the cooling water control (ECO-versions only)
The ECO -versions of the Scrubber are equipped with a cooling water control ensuring the flow of the cooling water is switched on every time the K-415 is switched on by the digestion instrument and is turned off the same time, the digester is turned off. (Assumed the external cooling water source is always turned on).
The cooling water control a can be found on the rear side of the instrument with cooling water inlet b at the bottom and the cooling water outlet on top. The cooling water inlet can be horizontally swivelled around in a range of 180 degrees. This makes it possible to orient the inlet towards the available cooling water supply.
To swivel the cooling water inlet, proceed as follows:
• Loosen the nut on the bottom of the inlet c , using the matching end of the provided Multi-tool d .
• Swivel the inlet b to the appropriate position.
• Tighten the nut c with the Multi-tool d .
NOTE
After swiveling the cooling water inlet to the preferred position make sure the fixing nut c is tight and check all connections and tubing of the cooling water control for tightness.
3
1
2
8
7
4
5
6
Fig. 5.10 Swivelling the cooling water inlet
• Connect the provided hose for the water control e on one side to the inlet b of the cooling water control and tighten it with the matching end of the Multi-tool d .
• Connect the provided adapter f with sieve g and sealing h to the water source and tighten it using the Multi-tool.
• Connect the other end of the hose to the adapter at the water source and tighten it.
• Check all connections for tightness before putting the instrument into operation.
29 K-415 Operation Manual, Version B
5 Putting into operation
5 .7 Hose connections
NOTE
Use clips and cable ties where necessary to secure the hoses in place.
5 .7 .1 Hose connections of the DuoScrub
The DuoScrub consists of the neutralization and the adsorption vessel.
To establish the hose connections, proceed as follows:
• Connect the adsorption vessel c to the bypass valve d using the PTFE hose and secure it with the GL 14 hose connectors at both ends.
• Connect the emission source via a Woulff bottle to the neutralization vessel b and secure all connections with hose clamps.
1
3
2
30
4 a Neutralization stage b Inlet for fumes from the emission source c Adsorption vessel
Fig. 5.11: Hose connections of the DuoScrub
5 d Bypass valve e Silencer
K-415 Operation Manual, Version B
5 Putting into operation
5 .7 .2 Hose connections for the TripleScrub
The TripleScrub consists of the neutralization vessel, the adsorption vessel, and the condenser unit.
To establish the hose connections, proceed as follows:
• Put hose connectors GL 14 with seals on all PTFE hoses.
• Connect the emission source to the condenser inlet e
.
• Connect the condenser outlet f
to the neutralization vessel a
.
• Connect the adsorption vessel b to the bypass valve c
.
• Cut off a piece of the provided silicone hose and connect the cooling water source to the cooling water inlet of the condenser g
. Secure it with a hose clamp.
• Cut off a piece of the provided silicone hose and connect the cooling water outlet of the condenser h to the waste water system.
1
2
9
5 6 7 8
3 a Neutralization stage b Adsorption vessel c Bypass valve d Silencer e Inlet for fumes from emission source
Fig. 5.12: Hose connections for the TripleScrub
4 f Outlet to neutralization vessel (top) g Cooling water inlet (bottom) h Cooling water outlet (top) i Condenser
31 K-415 Operation Manual, Version B
5 Putting into operation
5 .7 .3 Hose connections for the TripleScrub ECO
The TripleScrub ECO consists of the neutralization, the adsorption vessel, the condenser unit and the cooling water control.
To establish the hose connections, proceed as follows:
• Put hose connectors GL 14 with seals on all PTFE hoses.
• Connect the emission source to the condenser inlet g
.
• Connect the condenser outlet h
to the neutralization vessel a
.
• Connect the adsorption vessel b to the bypass valve e
.
• Connect your cooling water source to the cooling water tube of the water control c using the provided adapter with sieve and tighten it (see chapter 5.6).
• Cut off a piece of the provided silicone hose and connect the cooling water outlet d of the water control c to the cooling water inlet i
of the condenser. Secure both connections with hose clamps.
• Cut off a piece of the provided silicone hose and connect the cooling water outlet j
of the condenser k to the waste water system.
1
2
11
7 8
4
5
3 a Neutralization stage b Adsorption vessel c Water control d Water control (outlet) e Bypass valve f Silencer
Fig. 5.13: Hose connections for the TripleScrub ECO
9 10
6 g Inlet from emission source (digester) h Outlet to neutralization vessel (top) i Cooling water inlet (bottom) j Cooling water outlet (top) k Condenser
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5 Putting into operation
5 .7 .4 Hose connections for the QuadScrub ECO
The QuadScrub ECO consists of the neutralization, the adsorption vessel, the condenser, the cooling water control and the reaction stage.
To establish the hose connections, proceed as follows:
• Put hose connectors GL 14 with seals on all PTFE hoses.
• Connect the emission source to the condenser inlet i
.
• Connect the condenser outlet j
to the neutralization vessel a
.
• Connect the adsorption vessel b to the top of the reaction tubelet c
.
• Connect the reaction tubelet (connection on the side d
) to the bypass valve g
.
• Connect your cooling water source to the cooling water tube of the water control e using the provided adapter with sieve and tighten it (see chapter 5.6).
• Cut off a piece of the provided silicone hose and connect the cooling water outlet f of the water control e
to the cooling water inlet k
of the condenser m
. Secure both connections with a hose clamp.
• Cut off a piece of the provided silicone hose and connect the cooling water outlet l
of the condenser m to the waste water system.
1
2
33
3
13
4
9 10
11 12
6
7
5 a Neutralization stage b Adsorption vessel c Reaction stage (upper port) d Reaction stage (side port) e Water control f Water control (outlet) g Bypass valve
Fig. 5.14: Hose connections for QuadScrub ECO
8 h Silencer i Inlet from emission source (digester) j Outlet to neutralization vessel (top) k Cooling water inlet of condenser (bottom) l Cooling water outlet of condenser (top) m Condenser
K-415 Operation Manual, Version B
5 Putting into operation
5 .8 Electrical connections
Notice
Risk of instrument damage by wrong mains supply.
• External mains supply must meet the voltage given on the type plate.
• Check for proper grounding.
• Exchange defective cabling instantly.
• Make sure the used digester and the K-415 are suitable for the same power system (voltage and frequency) when both instruments share the same power source.
Connect the Scrubber K-415 to the mains with the power cord contained in the scope of delivery.
To start the Scrubber automatically at the same time the digestion process starts, connect it to the
SpeedDigester K-439, to a Digest System K-437 or to a Digest Automat K-438/K-432 with the optional connection cable.
NOTE
To cut the power in case of an emergency by unplugging, the instrument or any other item must not block the mains plug! In this case, the plug must be able to be pulled out instantly.
5 .9 Preparing washing solutions
!
WARNING
Serious chemical burns by corrosives.
• Observe all data sheets of the used chemicals.
• Handle corrosives in well ventilated environments only.
• Always wear protective goggles.
• Always wear protective gloves.
• Always wear protective clothes.
• Do not use damaged glassware.
34 K-415 Operation Manual, Version B
5 Putting into operation
5 .9 .1 Washing solutions for acidic vapors and gases
• Sodium hydroxide 8-10 %, max. 20 %
• Sodium carbonate
– dissolve 600 g Na
2
– dissolve 1.7 kg Na
2
CO
CO
3 in 3 L distilled warm water, or
3
· 10 H
2
O in 3 L distilled warm water
Color indicator
A color indicator is added to the washing solution to assess its washing power visually as well.
We recommend to use a spatula tip of color indicator for 3 L of washing solution.
Bromothymol blue serves as a stan dard indicator. The transition area here is between pH 6.0 to 7.6.
Thus the fresh solution has a blue color while the neutralized or acidic solution has an orange yellowish color.
Depending on the application purpose, other suitable color indicators should be used.
5 .9 .2 Washing solutions for alkaline vapors and gases
• Hydrochloric acid, max. 15 %
• Sulphuric acid, max. 20 %
Depending on the area of application, it is recommended to use different washing solutions or concentrations. The Scrubber K-415 is supplied ex works with a base-resistant lip gasket.
NOTE
For operating with acid washing solutions, an acid-resistant lip gasket should be used.
Color indicators
Table 5-1: Indicators for washing solutions for alkaline vapors and gases
Name Transition pH range Color change
Bromocresol green 3.8 - 5.4
yellow to blue
Bromothymol blue
Methylen red
5.8 - 7.6
4.4 - 6.2
yellow to blue yellow to red
35 K-415 Operation Manual, Version B
5 Putting into operation
5 .10 Filling up the prepared washing solution
!
WARNING
Risk of serious chemical burns by corrosives.
• Allways use the glass handles of the neutralization vessel to lift or carry it.
• Never try to lift or carry the neutralization vessel while holding it on the cover of the neutralization vessel.
To fill up the washing solution, proceed as follows:
• Remove the adsorption vessel a by gently pulling it upwards. (If available store it on the tray f .)
• Loosen the hose connector GL 14 b at the neutralization vessel and pull off the hose. (If available store it on the tray f .)
• Take the neutralization vessel with the attached cover away from the instrument. Lift or carry the neutralization vessel solely by using the glass handles h of the vessel.
• Remove the cover of the neutralization vessel c togehter with the attached swirl discs d .
• Carefully pour the prepared washing solution into the neutralization vessel and fill up to the blue wavy optimal filling mark g .
• Reassemble the instrument in the reverse order.
NOTE
Make sure the cover is pressed firmly against the neutralization vessel to ensure tightness of the system!
2
1
3
6
5
4
7
8 a Adsorption vessel b Nut GL 14 c Cover with swirl discs d Washing insert
Fig. 5.15: Filling up the washing solution e ON/OFF switch f tray g filling mark h glass handles
NOTE
For information on how and when to exchange the washing solution, see chapter 7.6.
36 K-415 Operation Manual, Version B
5 Putting into operation
5 .11 Preparation of the adsorption vessel
NOTE
When you carry out Kjeldahl digestions, the suction capacity might become too high. Therefore we recommend to fill activated charcoal into the adsorption vessel and to add glass wool at both ends.
The glass wool prevents charcoal from being drawn into the vacuum pump. The activated charcoal should be grainy with a particle size of 2 to 6 mm.
!
CAUTION
Risk of instrument damage and risk of serious chemical burns by corrosives.
• Never use charcoal in the form of powder or with a particle size below 2 mm - otherwise the adsorption vessel will get clogged and as a result the pump will get damaged.
Fig. 5.16: Adsorption vessel with activated charcoal and glass wool
5 .12 Filling the reaction stage
For digestions with aqua regia it becomes necessary to fill the reaction stage with around 350 mL of a saturated FeSO
4
solution (~27 g/100 mL) to dispose of the nitrous gases.
37 K-415 Operation Manual, Version B
6 Operation
38 K-415 Operation Manual, Version B
6 Operation
6 Operation
This chapter gives examples of typical instrument applications and instructions on how to operate the instrument properly and safely.
!
CAUTION
Risk of minor or moderate cuts when handling damaged glass parts.
• Handle glass parts with care.
• Visually inspect every glass part before mounting.
• Exchange damaged glass parts immediately.
• Do not touch cracks or bits of broken glass with bare hands.
ATTENTION
Switch on the K-415 before a connected instrument produces gases. Check the level of the liquid in the neutralization vessel before putting the scrubber into operation - the optimal liquid level can be checked against the blue filling mark (wave) on the neutralization vessel.
If the K-415 is controlled via a digester do not switch the K-415 off. If the K-415 is equipped with cooling water control ( ECO -versions) leave the external cooling water supply switched on as well.
6 .1 Typical applications
Table 6-1: Typical applications
Gases and vapors Chemical formula
Kjeldahl digestions SO
2
, H
2
SO
4
Sulfur dioxide SO
2
Sulfuryl chloride
Hydrochloric or hydrobromic acids
Thionyl chloride
Cyanuric chloride
Carbonic acid chloride
Ammonia
Nitrous oxides (nitrous gases)
Nitric acid / aqua regia
Chlorine, bromine, iodine
Thiophenols
Thioalcohols, mercaptan
Hydrogen sulphide
Carbon disulphide
SO
2
Cl
2
HCI, HBr
SOCl
2
C
3
N
3
Cl
3
R-COCI
NH
3
NO
X
Cl
2
, Br
2
, J
2
Ar-SH
R-SH
H
2
S
CS
2
Neutralization (stage 2) saturated soda / NaOH
8 - 10 % (max. 20 %) saturated soda / NaOH
8 - 10 % (max. 20 %)
NaOH 8 - 10 % (max. 20 %)
NaOH 8 - 10 % (max. 20 %)
Specific reactions (stage 4)
NaOH 8 - 10 % (max. 20 %)
NaOH 8 - 10 % (max. 20 %)
NaOH 8 - 10 % (max. 20 %)
HCI max. 15 % / H
2
SO
4
max. 20 %
NaOH 20 % FeSO
4 saturated
NaOH 8 - 10 % (max. 20 %)
NaOH 8 - 10 % (max. 20 %)
NaOH / javelle water
NaOH 8 - 10 % (max. 20 %)
NaOH 8 - 10 % (max. 20 %)
FeSO
4 saturated
KMnO
4
saturated
KMnO
4 saturated
KMnO
4
saturated
KMnO
4
saturated
39 K-415 Operation Manual, Version B
7 Maintenance and repairs
6 .2 Operation
2
2
1
• Switch on the power switch a .
• Make sure that the cooling water flow rate
>1.2 L/min ( ≤ 25 °C) is pulse-free and does not exceed 2.7 bar.
• The ECO -models of the Scrubber K-415 come equipped with an automatic water-control. The automatic water control will start the flow of cooling water automatically once the instrument is switched on and stop it, when the instrument is switched off (this is also valid, if the K-415 is controlled via a digester).
• The suction performance can be regulated, using the bypass valve b . To reduce the suction perfomance, turn the knob counter-clockwise.
Turning the knob clockwise will close the valve and maximise the suction performance.
2
Fig. 6.1: Operation
NOTE
For most applications it is recommended to keep the bypass valve completely closed and to work with the maximum available suction performance.
In case you find out the suction performance is to high for your requirements (e.g. for small sample volumes or small numbers of samples) turn the knob counter-clockwise until the suction performance is reduced to an adaquate proportion.
The bypass valve can be adjusted in the range of 100 to 400 mbar below atmospheric pressure.
40 K-415 Operation Manual, Version B
7 Maintenance and repairs
7 Maintenance
This chapter gives instructions on all maintenance work to be performed in order to keep the instrument in good working condition.
NOTE
Use only genuine consumables and spare parts for any maintenance and repair work in order to assure warranty and continued system performance. Any modifications of the Scrubber or parts of it need prior written permission of the manufacturer.
!
WARNING
Death or serious burns by electric current.
• Switch off the instrument and disconnect the power cord before performing any maintenance work.
• Do not spill liquids over the instrument or parts of it.
!
CAUTION
Risk of minor or moderate cuts when handling damaged glass parts.
• Handle glass parts with care.
• Visually inspect every glass part for good condition before mounting.
• Exchange damaged glass parts immediately.
• Do not touch cracks or bits of broken glass with bare hands.
NOTICE
Risk of housing and instrument damage by liquids and detergents.
• Do not spill liquids over the instrument or parts of it.
• Wipe off any liquids instantly.
• Use ethanol or soapy water as detergent only.
Table 7-1: Service intervals
Part
Housing
Glass parts
Hoses /hose connectors
Sealing system
Service intervals
Check and clean once a week
Check and clean once a month (or if required)
Check and clean once a week
Check and clean once a month (or if required), replace sealing once a year
Washing insert
Washing solution
Charcoal in adsorption vessel
Check from time to time
Check and replace in appropriate time
Replace if necessary
Pump Flush once a week or after hard work
Hose water control / condenser Check on a monthly base
Hose water control feed
Rubber strap
Power supply fuses
Check sieve on a monthly base, check hose once a year check and replace if required
Replace if necessary
7.5
7.6
7.7
7.8
7.9
7.10
See chapter
7.1
7.2
7.3
7.4
7.11
41 K-415 Operation Manual, Version B
7 Maintenance and repairs
Table 7-1: Service intervals
Part
Silencer
Functional test
Customer Service
Service intervals
Replace once a year
See chapter
7.12
7.13
7.14
7 .1 Housing
Check the housing for defects (switches, plugs) and clean it once a week with a damp cloth.
7 .2 Glass parts
Take out and clean the glass parts once a month or if required with commercially available cleaning agents or in an ultrasonic bath. After the glass parts have been cleaned and fully dried, check each part visually for cracks, scratches and for any parts or sections that might have splintered off. Take out and replace any damaged glass parts.
7 .3 Hoses / hose connectors
Visually examine the hose connections regularly. When hoses become cracked and brittle, replace them with new hoses.
Grease all joints on the condenser side regularly to achieve optimum tightness of the system.
Flush out the hoses at least once a week with water or ethanol.
For the ECO -versions check the cooling water hose for tightness and clean the sieve of the adapter on a regular base.
7 .4 Sealing system
ATTENTION
When removing and reinstalling the seals and gaskets, make sure not to damage them. Always move them perpendicularly to the axis of the glass parts and ensure no damage occurs to the sealing lip.
Never apply grease to the seals and never touch them with sharp objects, otherwise they will get damaged.
7 .4 .1 Cleaning the gaskets
To prolong the lifetime of the gaskets (lip-gasket, gasket ring), rinse them at least once a month or if required (e.g. when exchanging the washing solution) with water, especially if working with crystalline products. Afterwards, dry them with a soft cloth.
7 .4 .2 Replacing the seals / GL 14 connector
Seals are subject to wear and tear, thus you should check them regularly and replace them, if necessary, e.g. if the system becomes untight.
We recommend to replace the seals periodically as follows:
42 K-415 Operation Manual, Version B
7 Maintenance and repairs
Table 7-2: Replacing seals and silencer unit
Position in Fig. 10.1
Order no.
Description
8 + 7
30 + 7
28
13
17 + 7
23
32
3
41
39
040296
040295
037928
003575
041999
037873
037925
037871
003576
003575
Set of seals / connectors (straight)
Set of seals / connectors (bent)
O-ring to adapter (37777)
Gasket SVL 42 x 30 PTFE
Lip gasket GL 14 (FEP)
Seal for receiving vessel
Gasket ring
Silencer unit
Gasket SVL 22 x 16 PTFE (with silicone bearing)
Gasket SVL 42 x 30 PTFE
Replacing interval once a year once a year once a year once a year once a year once a year once a year once a year once a year once a year
7 .5 Washing insert
The washing insert must be cleaned from time to time and the lip gasket must be replaced when brittle.
8
7
6
5 a Nut M20 b Swirl disc c Spacer tube d Swirl disc holder e Lip gasket f Cover g O-ring 24 x 2.5
h Hose connector adapter M20 GL 14
4
2
3
2
1
Fig. 7.1: Exploded view of the washing insert
To (re)assemble the washing insert, proceed as follows:
• Insert the lip gasket e into the cover of the neutralization vessel f .
• Place the cover of the neutralization vessel f on the swirl disc holder d .
• Screw on the adapter h with the O-ring g and tighten it.
• Insert the first swirl disc b .
• Insert the spacer tube c .
• Insert the second swirl disc b .
• Screw the washing insert into the nut a .
• Insert the complete washing insert into the neutralisation vessel.
• Press the cover f on the neutralization vessel and center the neutralization vessel.
43 K-415 Operation Manual, Version B
7 Maintenance and repairs
7 .6 Washing solution
Used washing solutions may impair the functionality of the Scrubber K-415 especially in the range of the neutra lization point as a result of strong foaming. Changing the washing solution in appropriate time (when the color indicator undergoes a color change) keeps the adsorption stage and/or reaction stage from getting soiled and pre vents the possibility of the pump getting damaged. For a discription of how to prepare and fill up the washing solution, see chapters 5.9 and 5.10.
NOTE
Make sure to dispose of the used washing solution according to your laboratory guidelines.
7 .7 Active charcoal
Exchange the active charcoal as soon as it clumps together or white crystals or other residues become visible.
7 .8 Pump
Flush the pump once a week or after hard use.
To flush the pump, proceed as follows:
• Close the bypass valve a completely (for maximum suction power).
• Disconnect the suction hose d from the absorption vessel and put it into a suitable vessel c with at least 500 mL of distilled water.
• Disconnect the silencer and remove it.
NOTICE
Risk of a water leakage and power failure.
• Do not pull on the pump output hose.
• Place a suitable vessel b on the pump output.
• Switch on the device and collect the waste water from the pump.
• Flush the pump until the collected waste water is clear
44 K-415 Operation Manual, Version B
7 Maintenance and repairs
Fig. 7.2: Flushing the pump
7 .9 Hose cooling control / condenser
Check the hose monthly and replace it as soon as it becomes porous.
7 .10 Hose water control feed
• Check the sieve once a month for residues and clean it if necessary.
• Check the adapter, its sealings and the sieve on a yearly base and replace defective parts.
7 .11 Power supply fuses
1
2
To replace the power supply fuses, proceed as follows:
• Pull out the power supply cable.
• Remove the fuse holder a .
• Replace the defective fuse with a new fuse b of the same type:
– 100 V: T2A L 250 V
– 120 V: T2A L 250 V
– 230 V: T1A L 250 V
• Put the fuse holder back.
Fig. 7.3: Replacing the power supply fuses
45 K-415 Operation Manual, Version B
8 Troubleshooting
7 .12 Silencer
Replace the silencer once a year.
7 .13 Functional test
A functional test to check whether the bypass valve functions properly and if the complete system of the K-415 is tight can be performed by your service technician. Please contact your BUCHI service center concerning this matter.
7 .14 Customer service
Only authorised service personnel are allowed to perform repair work on the instrument. These persons have a comprehensive technical training and knowledge of possible dangers which might arise from the instrument.
Addresses of official BUCHI customer service offices are given on the BUCHI website under: www.buchi.com. If malfunctions occur on your instrument or you have technical questions or application problems, contact one of these offices.
The customer service offers the following:
• Spare part delivery
• Repairs
• Technical advice
• Troubleshooting
• Instrument qualification (IQ) and operative qualification (OQ)
46 K-415 Operation Manual, Version B
8 Troubleshooting
8 Troubleshooting
This chapter helps to resume operation after a minor problem has occurred with the instrument. It lists possible occurrences, their probable cause and suggests how to remedy the problem.
The troubleshooting table below lists possible malfunctions and errors of the instrument. The operator is enabled to correct some of those problems or errors by him/herself. For this, appropriate corrective measures are listed in the column “Corrective measure”.
The elimination of more complicated malfunctions or errors is usually performed by a BUCHI technical engineer who has access to the official service manuals. In this case, please refer to your local BUCHI customer service agent.
8 .1 Malfunctions and their remedy
Table 8-1: General malfunction and their remedy
Malfunction Possible cause
K-415 does not work No mains connection?
Fuses defective?
Mains switch defective?
Pump does not work
No digestion running while instrument is controlled by digester?
Wiring defective?
Pump defective?
Cooling water not running External cooling water source switched off?
Loss of cooling water Untight hose connections?
Fumes are not exhausted during digestion (Scrubber suction capacity too weak)
Suction system leaking?
Hose bent or porous?
Adsorption vessel clogged?
Washing solution dirty?
Adsorbents clogged?
Pump dirty?
Silencer unit clogged?
Overpressure valve dirty?
Cock of TKN receiving vessel open?
Wrong adjustment of bypass valve?
Fumes are exhausted too fast during digestion
(Scrubber suction capacity too strong)
Suction system clogged?
Adsorbents clogged?
Silencer unit defective?
Wrong adjustment of bypass valve?
Bypass valve defective?
Unsufficient neutralization Washing solution used up?
Swirl discs blocked?
Corrective measure
Check whether the instrument is connected to the mains.
Replace the defective fuses.
Contact the BUCHI customer service.
Wait for digestion to start.
Contact the BUCHI customer service.
Contact the BUCHI customer service.
Switch external cooling water source on.
Check hose connections and water control.
Tighten the hose and glass connections .
Check the hoses.
Check the adsorption vessel and the contained activated charcoal.
Exchange the washing solution.
Renew the adsorbents.
Clean the pump.
Replace the silencer unit.
Contact the BUCHI customer service.
Close the cock.
Readjust the bypass valve.
Check all stages and the connected digestion unit as well.
Exchange the adsorbents.
Replace the silencer unit.
Readjust the bypass valve.
Contact the BUCHI customer service.
Exchange the washing solution.
Clean swirl discs and washing solution.
47 K-415 Operation Manual, Version B
9 Shutdown, storage, transport and disposal
48 K-415 Operation Manual, Version B
9 Shutdown, storage, transport and disposal
9 Shutdown, storage, transport and disposal
This chapter instructs how to shut down the instrument, how to pack it for storage or transport, and specifies the storage and shipping conditions.
!
WARNING
Death or serious poisoning by contact or incorporation of harmful substances.
• Wear safety goggles
• Wear safety gloves
• Wear a laboratory coat
• Clean the instrument and all accessories thoroughly to remove possibly dangerous substances
• Do not clean dusty parts with compressed air
• Store the instrument and its accessories at a dry place in its original packaging
9 .1 Storage and transport
Switch off the instrument and remove the power cord. To disassemble the Scrubber K-415 follow the installation instructions in section 5 in reverse order. Clean the instrument thoroughly! Remove all liquids and dusty residues before packaging the instrument.
9 .2 Disposal
To dispose of the instrument in an environmentally friendly manner, a list of materials is given in chapter 3. This helps to ensure that the components are separated and recycled correctly.
Please follow valid regional and local laws concerning disposal.
49 K-415 Operation Manual, Version B
10 Spare parts
50 K-415 Operation Manual, Version B
10 Spare parts
10 Spare parts
This chapter lists spare parts, accessories, and options including their ordering information. Order the spare parts from BUCHI. Always state the product designation and the part number when ordering spare parts.
Use only genuine BUCHI consumables and genuine spare parts for maintenance and repair to assure good system performance and reliability. Any modifications to the spare parts used are only allowed with the prior written permission of the manufacturer.
10 .1 Spare parts on the exploded instrument view
5
4
9
10
1
7
30
2
3
6
14
12
13
11
16
17
8
7
7
30
17
29
28
15
18
41 42 17 7
7
19
20
17
43
34
36
17 7 35
23
27
26
25
40
39
38
37
33
32
24
23
22
31
21
Fig. 10.1: Spare parts on the exploded instrument view
51 K-415 Operation Manual, Version B
10 Spare parts
Table 10-1: Spare parts on the exploded instrument view
Position Product Order number Position Product
1
2
3
4
5
6
20
21
22
Tray for adsorption storage (with screw)
Anti-seismic-tie-down
Silencer unit
(filled with polyester fibres)
Neoprene hose (8/2 x 250)
Hose clamp (10 - 16 mm)
Receiving vessel
7 Screw cap GL 14 (Set of 10 pcs.)
8 + 7 Connector straight for GL 14 with FPM sealing (set of four, including screw caps)
9 Rubber strap
10
11
12
Condenser S35
Hose condenser / washing solution (FEP)
Carrier plate for condeser
13
14
Screws for carrier plate (M4x16)
Catchpot clip S35
11057332 23
- 24
11056985 25
11056456 26
043297 27
11057153 28
041956 29
040296 30 + 7 Connector bent for GL 14
(set of four, including screw caps)
11059813 31
11057152 32
11057155 33
- 34
- 35
003275 36
15
16
Hose connection S19 (ball joint)
Ball joint clamp
17 + 7 Gasket FEP (GL 14) (set of 10, incl. screw caps)
18 Receiving vessel with cock
(TKN-set)
19 Hose clamp (10 - 16 mm)
11057159 37
11057149 38
041999 39
11056979 40
043297 41
Tube for TKN-set (1.5 m, 8/12)
Neutralization vessel (P+G)
Nut M20
020136 42
11057138 43
037855
Swirl disc
Spacer tube
Swirl disc holder
Lip gasket
EPDM (resistant against bases)
FPM (resistant against acids)
Cover of neutralization vessel
O-Ring 24 x 2.5
(with hose connector adapter)
Hose connector adapter M20 GL
14
Reaction vessel, 1.0 L
Gasket ring
Screw cap SVL 42
Introduction tube assembly
Hose reaction / pump (FEP)
Hose adsorption / reaction (FEP)
Axial Gasket ring
Adapter piece for adsorption
Gasket SVL 42 x 30 PTFE
Adsorption vessel
Gasket SVL 22 x 16 PTFE
(with silicone bearing)
Adapter SVL 22 / GL 14
Hose adsorption / pump
Order number
037777
040295
037972
11057154
037821
037852
037851
037874
038064
11057139
037928
037797
037925
003551
037778
11057157
11057156
049485
11057147
003575
037774
002070
52 K-415 Operation Manual, Version B
10 .2 Miscellaneous
Table 10-2: Miscellaneous
Product
Set of sealings FPM (10 pieces)
Set of screw caps GL 14 (10 pieces)
Set of screw caps GL 14 and sealings FEP (10 pieces)
10 Spare parts
Order number
040040
041956
041999
53 K-415 Operation Manual, Version B
11 Declarations and requirements
54 K-415 Operation Manual, Version B
11 Declarations and requirements
11 Declarations and requirements
11 .1 FCC requirements (for USA and Canada)
English:
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to both Part 15 of the FCC Rules and the radio interference regulations of the Canadian
Department of Communications. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
Français:
Cet appareil a été testé et s’est avéré conforme aux limites prévues pour les appareils numériques de classe A et à la partie 15 des réglementations FCC ainsi qu’à la réglementation des interférences radio du Canadian Department of Communications. Ces limites sont destinées à fournir une protection adéquate contre les interférences néfastes lorsque l’appareil est utilisé dans un environnement commercial.
Cet appareil génère, utilise et peut irradier une énergie à fréquence radioélectrique, il est en outre susceptible d’engendrer des interférences avec les communications radio, s’il n’est pas installé et utilisé conformément aux instructions du mode d’emploi. L’utilisation de cet appareil dans les zones résidentielles peut causer des interférences néfastes, auquel cas l’exploitant sera amené à prendre les dispositions utiles pour palier aux interférences à ses propres frais.
55 K-415 Operation Manual, Version B
11 .2 Declaration of conformity
Quality in your hands
BUCHI Affiliates:
BÜCHI Labortechnik AG
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T +41 71 394 63 63
F +41 71 394 65 65 [email protected]
www.buchi.com
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IT – 20010 Cornaredo (MI)
T +39 02 824 50 11
F +39 02 57 51 28 55 [email protected]
www.buchi.it
BUCHI Russia/CIS
United Machinery AG
RU – 127787 Moscow
T +7 495 36 36 495
F +7 495 981 05 20 [email protected]
www.buchi.ru
Nihon BUCHI K.K.
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T +81 3 3821 4777
F +81 3 3821 4555 [email protected]
www.nihon-buchi.jp
BÜCHI Labortechnik GmbH
DE – 45127 Essen
Freecall 0800 414 0 414
T +49 201 747 490
F +49 201 747 492 0 [email protected]
www.buechigmbh.de
BÜCHI Labortechnik GmbH
Branch Office Benelux
NL – 3342 GT
Hendrik-Ido-Ambacht
T +31 78 684 94 29
F +31 78 684 94 30 [email protected]
www.buchi.be
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CN – 200052 Shanghai
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F +86 21 5230 8821 [email protected]
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F +33 1 46 86 00 31 [email protected]
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GB – Oldham OL9 9QL
T +44 161 633 1000
F +44 161 633 1007 [email protected]
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BUCHI Support Centers:
South East Asia
BUCHI (Thailand) Ltd.
TH-Bangkok 10600
T +66 2 862 08 51
F +66 2 862 08 54 [email protected]
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Latin America
BUCHI Latinoamérica Ltda.
BR – Valinhos SP 13271-570
T +55 19 3849 1201
F +41 71 394 65 65 [email protected]
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TH – Bangkok 10600
T +66 2 862 08 51
F +66 2 862 08 54 [email protected]
www.buchi.co.th
Middle East
BUCHI Labortechnik AG
UAE – Dubai
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F +971 4 313 2861 [email protected]
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IN – Mumbai 400 055
T +91 22 667 75400
F +91 22 667 18986 [email protected] www.buchi.in
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F +62 21 537 62 17 [email protected]
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KR – Seoul 153-782
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www.buchi.kr
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US – New Castle,
Delaware 19720
Toll Free: +1 877 692 8244
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BUCHI do Brasil
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DE – 69190 Walldorf
T +49 6227 73 26 60
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We are represented by more than 100 distribution partners worldwide.
Find your local representative at: www.buchi.com
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