wtw TresCon Operating instructions

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, S

AFETY, on page 2-1

in the T

ERMINAL volume of this manual.

Copyright

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

Pges Overview

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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, S

AFETY, 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

Overview Pges

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ba43121e03 01/2011

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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ba43121e03 01/2011

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

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

Overview Pges

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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:

z Oxidative digestion of organic phosphorous compounds and

hydrolysis of tripolyphosphates.

z Determination of the total orthophosphate PO4

3-

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 (PO4

3-

) at the end:

z Oxidation of organic phosphorous compounds and phosphorous

compounds with lower oxidation levels. Under the effect of the acid,

peroxydisulfate S

2

O

8

2-

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.

z Hydrolysis 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:

z Under 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.

z The phosphorous molybdenum acid is reduced by the ascorbic acid.

Pges Overview

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ba43121e03 01/2011

At the same time, part of the molybdenum VI is converted to

molybdenum V. The compound that arises is colored blue

(phosphorous molybdenum blue).

z The 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:

z P511: TresCon Pges analyzer module

z Operating manual to be added to the main folder

z Cool box KB/P511

z Reagents 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 Na

2

EDTA for 10 L

cleaning solution

z 1 x BEH/ T 10: empty 10 L container to prepare the cleaning solution

z 1 x BEH/ T 1,5: empty 1.5 L container for cleaning solution

z 1 x BEH/ T 1,5: empty 1.5 L container for standard A (H2O dist.)

z 1 x screw cap for standard A, yellow

z 1 x screw cap for standard B, orange

z 1 x screw cap for cleaning solution, blue

z 4 x screw cap for reagents A ... D, green

z 1 x TC/ÜB 1: Simple overflow vessel

z 4 x Wpack/P511, sets with spare tubes, altogether sufficient for a

typical yearly demand

Overview Pges

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ba43121e03 01/2011

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:

z Displacing the existing analyzer module to the right-hand mounting

slot (module 3, connection cable on the right side)

z Selection 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 I

NSTALLATION section in the TERMINAL volume of the operating

manual before starting the retrofit!

Pges Overview

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ba43121e03 01/2011

Installing the analyzer

module

Fig. 1-4 Remove the left cover plate

1 Switch off the TresCon at the power switch (on the mounting

stand).

2 Open the door of the TresCon.

3 At 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

TresCon NOx-N

Reinigungslösung

Cleaning Solution

Ablauf

V2

Thermoblock

Probe

Sample

V1

HO dest.

2

blau

blue

blau

blue

rot

red

Pumpschlauch Standard/Probe

blau / blau / blau

PumpTube Standard/Sample

blue / blue / blue

rot

red

P3

P1

10 fixing screws (B)

Overview Pges

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ba43121e03 01/2011

Fig. 1-5 Removing the center cover plate

4 Also 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

TresCon NOx-N

Reinigungslösung

Cleaning Solution

Ablauf

V2

Thermoblock

Probe

Sample

V1

HO dest.

2

blau

blue

blau

blue

rot

red

Pumpschlauch Standard/Probe

blau / blau / blau

PumpTube Standard/Sample

blue / blue / blue

rot

red

P3

P1

10 fixing screws (B)

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ba43121e03 01/2011

Fig. 1-6 Attaching the TresCon Pges module

5 Place 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

ReagenzA

(Peroxodisulfat)

ReagentA

(Peroxodisulfate)

ReagenzB

(Schwefelsäure)

ReagentB

(Sulphuricacid)

ReagenzC

()Ascorbinsäure

ReagentC

()Ascorbicacid

ReagenzD

(Molybdat-Lösung)

ReagentD

(Molybdatesolution)

A

u

fs

c

h

lu

ß

-

re

a

k

to

r

D

e

c

o

m

p

o

s

itio

n

r

e

a

c

to

r

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)

Overview Pges

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ba43121e03 01/2011

Fig. 1-7 Opening the mounting frame

6 Undo 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

ReagenzA

(Peroxodisulfat)

ReagentA

(Peroxodisulfate)

ReagenzB

(Schwefelsäure)

ReagentB

(Sulphuricacid)

ReagenzC

()Ascorbinsäure

ReagentC

()Ascorbicacid

ReagenzD

(Molybdat-Lösung)

ReagentD

(Molybdatesolution)

A

u

fs

c

h

lu

ß

-

re

a

k

to

r

D

e

c

o

m

p

o

s

itio

n

re

a

c

to

r

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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ba43121e03 01/2011

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

7 Connect 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

Overview Pges

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ba43121e03 01/2011

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

8 Connect the open end of the TresCon Pges outlet tube with the

outlet adapter in the bottom of the TresCon enclosure (see Fig.

1-10).

9 Connect 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

1 Swing 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.

2 Insert 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

1 Feed 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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ba43121e03 01/2011

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:

3 Feed 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

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

4 Briefly shake the closed container with cleaning solution

(NaOH).

5 Place a container of cleaning solution on the tray.

6 Connect 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.

7 Place a full container of standard A (dist. H2O) on the tray.

8 Connect the (yellow) screw cap with the (yellow) suction hose.

9 Place a full container of standard B on the tray.

10 Connect the (orange) screw cap with the (orange) suction

hose.

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wtw TresCon Operating instructions

wtw TresCon Operating instructions

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