1. The BioTector B3500ul TOC analyzer Service and Maintenance
November, 2017
Company Confidential

2. Service check sheet appropriate to the system being serviced.
This presentation should be viewed with the following documents available:
Manual appropriate to the system being serviced (example BioTector B3500ul manual).
Service check sheet appropriate to the system being serviced.
Service check sheet and manual for BioTector Compressor (if installed with BioTector B3500ul).
Note: all service kits contain the appropriate service check sheets as described above.

3. Safety:
Wear appropriate PPE!
The BioTector runs on mains electricity,
115V or 230V.
Some components may be hot.
The BioTector uses acidic and basic reagents.
Electrostatic devices may be present on some PCB’s. Always wear a grounding strap.

4. Use of thread tape on fittings in the BioTector.

5. Orientation of ferrules on fittings in the BioTector B3500ul.

6. The main components inside the outer compartment of the
BioTector B3500ul
Power PCB, with user terminals
for Power, Relay Contacts and
4-20ma signals
CO2 analyzer
24V DC
Power Supply
with voltage selector
Ozone Generator
Reagent Pumps
Cooler
On/Off switch
Sample Pump
Ozone Destructor
Manual, Calibration or Multi-stream valve
Reactor Valve
Sample valve
Exhaust Valve
Reactor with integral mixer

7. The main components inside the inner compartment of the
BioTector B3500ul
Oxygen Concentrator Tank
with regulator
Oxygen Concentrator Sieve Beds
Oxygen Concentrator
HEPA filter
Cooler Fan
Oxygen Controller Board with pressure sensors, flow sensor and control valve (MFC)
Instrument Air Inlet with Isolation valve
Oxygen Concentrator
Rotary valve
Mixer Reactor
Motor

8. BioTector Compressor.
The set point air pressure supplied from BioTector compressor should be 1.2 bar and the tube between compressor and the analyser should be as short as possible.
Compressor PCB
Excess air
discharge silencer
and
flow control valve
Air Outlet to
B3500ul.
Outlet can be
changed to
opposite side
of enclosure
if required
Compressor with
air inlet
filter / silencer
Cooling fan with
air filter
Power requirement, 230V 50Hz or 115V 60Hz, 300W.
Control cable from BioTector stops the compressor when the B3500ul is stopped (supplied with compressor).
Pneumatic connection for air: 3/8” Nylon or PTFE tube.

9. BioTector B3500ul 6 month service.
Actions to be carried out before starting service.
Service should only be carried out when the “SYSTEM STOPPED” message is displayed on the top left corner of the main Analysis Data screen or when the system is powered down. When “REMOTE STANDBY” or “SYSTEM RUNNING” message is displayed on the screen, stop the BioTector using the “Finish & Stop” or “Emergency Stop” function.
For system and personal safety, all reagent lines should be washed with water and then purged with air before the service procedures are carried out. In order to wash the reagent lines, connect all reagent tubes to a DI Water (or tap water) container. Go to Zero Calibration menu and activate “RUN REAGENT PURGE” function to wash the reagent lines with water. When the reagent purge with water is completed, remove the tubes from the water container and place them open to air. Using the same menu, select the “RUN REAGENT PURGE” function one more time to purge the reagent lines with air.
As the system may still contain small traces of reagents after the reagent purge cycles, it is strongly recommended to take the necessary safety precautions, such as wearing eye protection and gloves throughout the service.

10. To disconnect the power to the ozone destructor heater.
The ozone destructor heater power (24V DC) can be disconnected by un-plugging the wiring at the plug-in connector.
Please allow 1 hour for the ozone destructor to cool down. The ozone destructor should never be opened when it is hot as the threads may seize.
Below, the ozone destructor removed from the BioTector B3500ul. Note the “keyhole” cutouts in the bracket, which allows for the easy removal of the ozone destructor.

11. To replace the tube in the sample valve.
Replace the 6.4mm OD, 3.2mm ID EMPP 562 tubing used in the Sample Valve.
The tube should be installed smoothly with no twists.

12. To replace the tube in the WMM60 Sample Pump.
Open the hinged cover over the pump.
Open the locking lever for the fittings.

13. To replace the tube in the WMM60 Sample Pump.
Replace the tubing (6.4mm OD, 3.2mm ID EMPP 562 tubes) of the WMM60 Sample Pump. The WMM60 replacement tubes are supplied in the service kits.
The overall length of the tube is 156.5mm. If process conditions require this tube to be changed every 3 months, additional tubes are supplied in the service kit.
The tube should be installed smoothly with no twists.
Re-install the tube in the reverse order, ensuring that the locking lever is replaced securely.
The tube length guide can be used as a template for cutting the tube to the correct length.

14. To replace the tube in the stream or manual pinch valves.
Replace the 6.4mm OD, 3.2mm ID EMPP 562 tubing used in the stream or manual pinch valves, and any PP (Poly-Propylene) Y fittings.
Confirm that the ports are not blocked, especially the manual port, which may not have been used for some time.
The tube should be installed smoothly with no twists.

15. To open the inner compartment in the BioTector B3500ul.
Disconnect the PFA fitting above the cooler.
Remove the three nuts and open the analysis door.
Confirm that there are no leaks in the system.

16. To check the membrane valves in the BioTector.
The 6606 valve from Burkert has a membrane seal, which occasionally may have to be cleaned.
The valve can be disassembled as shown in the photograph on the left.
Note the yellow LED on the plug for the valve, which lights when the valve is powered.
The seal (shown left) should be free from particles and the surface of the seal should not be damaged.

17. Confirm reagent and ozone tubes are clean.
Check for possible build-up of salts or any material at any of the PFA T fittings and associated tubing located between the Ozone Generator and the Mixer Reactor. Clean the fittings and/or the tubing if necessary.
CAUTION: The tubes and fittings may contain acids and bases.
It should not be necessary to check the tubes or fittings at the reagent pumps.
Below, the base tube is confirmed as clean.

18. To check the Ozone Line filter.
Remove the Ozone Line Filter and wash it with DIW (or tap water). Dry the filter well and reinstall in place.

19. To check the WMM60 Sample pump rate after changing the tube.
When the EMPP tube has been changed in the WMM60 sample pump and pinch valves in the BioTector B3500ul, it is important to confirm that they are functioning correctly and all tubes were re-connected in the correct orientation.
By following this procedure, when the BioTector is re-started after service it will start up and run first time with no issues.
The expected pump rate of the WMM60 sample pump is detailed in the appropriate service check sheet.
This can be checked using a 10ml graduated cylinder, by running the pump from the appropriate simulate menu, and pumping water through them into the graduated cylinder. An example is shown opposite.
Any variation between tube batches is corrected when the zero and span calibration is carried out.

20. To check the FMM20 reagent pump rates.
Check both reagent pumps (acid and base).
With 400 pulses both pumps should be between 4.20 ml and 3.80 ml. Due to an internal system interlock, the total 400 pulses will need to be run as 2x 200 pulses.
The example opposite shows the acid pump being checked. Both pumps can be checked in the same location.
CAUTION: The reagent pumps should be tested pumping their correct reagents, therefore all necessary precautions required when handling acids and bases should be observed.
Important Note: For the correct operation of the system, the measured Acid and Base Pump rates must be identical or as close as possible. The maximum allowable difference in the measured volumes for acid and base injections above should not be more than 0.2ml. This figure is based on standard system operation conditions and may not cover systems built with specific configurations.
Details for adjusting the pump rate are on the next page.

21. To adjust the pumped volume in the FMM20 reagent pump.
CAUTION: The adjustment mechanism in the FMM20 pumps is sensitive. A rotation of a few degrees may be all that is required to get the correct pumped volume.
The FMM20 pump rate is adjusted with a small 1.5mm Allen wrench.
Turning anticlockwise (in the direction of the +) increases the pumped volume.
Turning clockwise (in the direction of the -) decreases the pumped volume.
Each notch on the adjustment dial is ~ 1ul. - +

22. To clean the FMM20 reagent pump.
CAUTION: This is not a service requirement,
If the reagent filter is correctly installed, the reagents are free of particles and the reagent lines are clean, the FMM20 pump should never require cleaning. However, should the FMM20 pump fail to pump due to particles in its pump-head, this is the procedure for cleaning it.
CAUTION: Some of these parts are very small, it is essential that absolute cleanliness is maintained at all times.
Reagent filter.
Step 1:
To remove the pump head from solenoid, first remove the 4 TX6 screws. Be careful not to dirty any parts.

23. To clean the FMM20 reagent pump.
Step 2:
Remove the reagent label (Acid or Base) from the pump-head.
Step 3:
Open the pump-head as shown.
Carefully clean the parts.
Re-assemble in reverse order.
Step 4:
The reagent tubes will have to be re-filled and the pumping rate of the pump will have to be checked after it is re-assembled.

24. Replace the filter mats, check the fan.
Replace the 100mm filter mats in fan and vent housing. The fan cover is levered out from the top with a screwdriver.
Slot for screwdriver.
Filter matt.
The operation of the fan can easily be checked with the fan cover off. Note that the fan is thermostatically controlled, but can be activated from the appropriate simulation menu.
To achieve optimal efficiency of the fan filter mats should be installed according to below diagram

25. To check the BioTector B3500ul CO2 Analyzer
The BioTector B3500ul CO2 analyzer is located in the top part of the enclosure and for service it needs to be removed from the enclosure.
To remove the analyser:
- disconnect the cable,
- unscrew 4 nuts and remove the blue clamps,
Below:
The B3500ul CO2 analyzer.
CAUTION:
During service, do not remove the cover over the detector electronics, or disassemble the detector section of the CO2 analyzer.
During service, do not remove any of the CO2 absorbers on the CO2 analyzer.
Do not remove the cover over the source electronics.

26. To check the BioTector B3500ul CO2 Analyzer
Clean the CO2 analyzer optics by removing the 4x M4x60 Allen bolts on the detector section.
If necessary, using the Lens Tissue (see item C6 in the service kits) clean the lenses, which are located on the detector and the source section of the CO2 Analyzer.
Replace the O-ring with the new O-ring provided.
Do not open.
Lens

27. General layout of BioTector CO2 Analyzer

28. To check that there is no CO2 on the oxygen supply.
Connection to CO2 analyzer
Check the purity of Oxygen: Power up the system for at least 10 minutes before the oxygen purity test is carried out.
Using the appropriate Simulate menu set the MFC flow to 10 l/h and flow oxygen gas through the CO2 analyzer for 5 minutes.
At the end of this period, the CO2 analyzer zero reading (CO2) should be within ± 2.5% of full scale of the CO2 analyzer range. Example, if the CO2 analyzer range is 10000ppm, then the CO2 analyzer zero reading should be typically ± 50ppm.
If the CO2 reading is outside the 2.5% level described above, check the purity of Oxygen gas.
Confirm that there is no CO2 in the oxygen gas by connecting the CO2 filter (used with the base container) between the Cooler and CO2 analyzer inlet port. See diagram opposite.
Temporary connections can be made with EMPP tube.
Set the MFC to 10 l/h. As the size of the CO2 filter is small, keep the 10 l/h gas flow running for at least for 5 minutes and record the CO2 zero readings at the end of the 5 minute period.
If the CO2 zero readings do not drop significantly with the CO2 filter in place, this will indicate that there is no CO2 contamination in the oxygen supply.
Connection from cooler.

29. To change the diaphragm in the NF300 mixer reactor
CAUTION: A torque screwdriver with TX20 bit calibrated to 1.4Nm, or 3mm Allen bit calibrated to 1.5Nm (for pumps built with metal cover plate) is a requirement for this service operation. Do not proceed unless you have this tool.
Remove the screws on the front of the Mixer Reactor and remove the reactor motor at the back.
Reactor and Mixer viewed from the side.
Note that the reactor is independently bolted to the door panel with 4 screws from the back (2 screws visible above). These should not be removed.
4 screws located here

30. To change the diaphragm in the NF300 mixer reactor
Example of mark
Hold the reactor diaphragm carefully using both hands and turn the diaphragm anti-clockwise to unscrew.
It is recommended to count the number of turns by putting a small mark on the diaphragm during this process. Note the number of turns.
Photo of NF300 Reactor Mixer, and replacement diaphragm. -

31. To change the diaphragm in the NF300 mixer reactor
CAUTION: it is essential that the diaphragm is tightened fully when service is complete.
If the diaphragm is not tight, the threads may become damaged due to the reciprocating nature of the pumping action in the pump.
Using both hands screw in the new diaphragm and tighten it firmly.
The typical minimum number of turns to tighten the diaphragm is from 7 to 8.5 turns. If a minimum number of 7 turns or the number of turns counted when the old diaphragm was removed is not achieved, the diaphragm must be removed and reinstalled.
Push the edge of the diaphragm down firmly into place.
When the installation of the diaphragm is complete, confirm that the diaphragm forms a “concave” shape at the center. In other words, when the diaphragm is installed correctly, the diaphragm should curve in forming a dent at the center.
If such dent has not formed, unscrew the diaphragm, confirm that the diaphragm is installed correctly and if necessary tighten the diaphragm more with additional turns. Hold the reactor diaphragm carefully using both hands and turn the diaphragm anti-clockwise to unscrew.

32. To change the diaphragm in the NF300 mixer reactor
CAUTION: A torque screwdriver with TX20 bit calibrated to 1.4Nm, or 3mm Allen bit calibrated to 1.5Nm (for pumps built with metal cover plate) is a requirement for this service operation. Do not proceed unless you have this tool.
IMPORTANT: Confirm that the sealing face at the back of the reactor is clean.
Install the reactor motor back onto the Mixer Reactor.
Tighten the screws/bolts. The torque should not exceed 1.4Nm (140cNm) for TX20 screws, or 1.5Nm (150cNm) for 3mm Allen bolts.
4 screws located here
Reactor and Mixer viewed from the side.
Example of torque screwdriver, with torque setting shown on dial.

33. To replace the catalyst in the ozone destructor.
The ozone destructor operates by catalytically converting ozone back into oxygen. For the destructor to operate correctly, the catalyst has to be in good condition, and the destructor has to be warm with a surface temperature of approximately ºC. The catalyst should be replaced every 6 months. It should also be replaced in the unlikely event that a smell of ozone emanates from the exhaust port of the BioTector.
Removal:
For maintenance, the easiest method of removing the ozone destructor is to remove both the ozone destructor and its mounting bracket as one unit (as shown in the photograph). The heater (24V DC power) can be un-plugged at the terminal block.
Service:
Prior to carrying out any service action, confirm that the temperature of the ozone destructor has dropped to ambient temperature level. Open the ozone destructor. The ozone destructor should never be opened when it is hot as the threads may seize. Confirm that the PTFE filters (discs) in the ozone destructor are clean. If there is any material build up (e.g. white powder), wash the filters using DI Water or tap water and dry. Do not use compressed air or any gas to clean the filters.
Replace the catalyst and glass wool in the ozone destructor. Note that in applications containing HCl or HF, the ozone destructor catalyst may require more frequent replacement.
Note: Do not use too much glass wool, as compacted glass wool this can restrict the flow of gas through the destructor.
Replace the o-ring with a new one. All the material required for this operation is contained in the 6 month service kit.
Re-install the ozone destructor, and re-connect the 24V DC power to the heater.
The main components of the ozone destructor are shown on the next slide. 

34. To replace the catalyst in the ozone destructor.
Viton
O-ring
Data on the heater used in the ozone destructor.
Voltage, 24v DC.
Current, 375ma.
Power 9W.
Resistance, 62 ohms
Heater
PTFE Disc
PTFE wool
PTFE Disc
PTFE
wool
Catalyst
The components in the ozone destructor.

35. To replace the catalyst in the ozone destructor.
Sectional drawing of the components of the ozone destructor.

36. To check the ozone generator current.
Using the appropriate Simulate menu, activate the OZONE GENERATOR and confirm that the Ozone Generator is working and current displayed on the LCD in the appropriate Simulate menu is 0.9 Amp.
DO NOT adjust the current unless running for at least 10 reactions has warmed up the ozone generator.
Any adjustments made when the generator is cold may result in a high input current when the generator warms up.
The normal warm running current should not exceed 1.0 Amps.
If the current has to be adjusted, the hole for adjusting the current is shown opposite (blue circle).

37. The CO2 filter used in the BioTector B3500ul TOC analyzer
To change the CO2 filter.
CO2 filters are used in the BioTector to remove CO2 gas from atmospheric air.
If the container holding the base solution is rigid, then as the base is pumped out of the container, a CO2 filter is used to clean the air entering the container.
If no CO2 filter is used, then the CO2 entering the base container will be absorbed into the base solution, and increase the TOC result.
Remove the tapes, which are used to seal the ends of the supplied CO2 filter. Replace the CO2 filter on the Base reagent container. Seal the Base container tightly.
This connection open to atmosphere.
Connection to reagent container.
The CO2 filter used in the BioTector B3500ul TOC analyzer

38. The use of the CO2 filter with the rigid base container.
To change the CO2 filter.
The use of the CO2 filter with the rigid base container.

39. To replace the HEPA filter.
Isolate the instrument air supply to the analyzer.
Go to the appropriate Simulate menu and set MFC to 60 l/h and run the oxygen supply until the flow drops to 0 l/h (until the oxygen tank is empty).
When there is no pressure in the system, remove the old HEPA filter (see blue circle), and install the new HEPA Filter carefully without contaminating the open tubing.
Turn the air supply on.

40. To check the system pressure settings.
Check the instrument air supply pressure at the filter pack pressure regulator. The pressure should be 1.5 bar (1.2 bar if BioTector compressor is used) when the oxygen concentrator is not using any instrument air. This typically cycles from 1.5 bar to 0.9 bar when the oxygen concentrator is running.
This pressure is also shown on the O2 Controller Status menu.
Check the O2 PRESSURE SENSOR in O2 Controller Status menu. The pressure should be between 390 mbar and 400 mbar at the idle 1 l/h oxygen flow. At a 60 l/h MFC SETPOINT setting, the pressure should not be less than 320 mbar.
The BioTector B3500ul contains a number of sensors to continuously monitor system performance, and report any issues which may occur. Details in the photograph.
Using the appropriate Simulate menu, check the operation of the Mass Flow Controller (MFC) and confirm that the MFC is working at various flow set points.
Regulator for adjusting oxygen pressure.
Sensor for incoming instrument air pressure. This is monitored and shown on the LCD.
Sensor for oxygen pressure. This is monitored and shown on the LCD.
Flow sensor and control valve which together make the Mass Flow Controller (MFC).

41. To check the BioTector B3500ul for leaks
and gas path blockages.
Check the BioTector B3500ul for any gas/fluid leaks by running the PRESSURE TEST cycle using the appropriate Process Test menu.
Check the BioTector B3500ul for any gas path blockages by running the FLOW TEST cycle using the appropriate Process Test menu. Both the EXHAUST TEST and SAMPLE OUT TEST should be run.
Details are in the next set of slides.

42. Pressure Test Purpose: Frequency of activation: Operation: Note:
To detect a leak or partial leak in the BioTector.
Frequency of activation:
Once per day, and when the BioTector B3500ul is started.
Operation:
The microcontroller activates the MFC with a gas flow of 40 LPH.
If there is no leak in the BioTector, the gas flow will drop eventually to 0 LPH.
If the gas flow drops below 4 LPH within 60 seconds, the pressure test passes.
If the gas flow is above 4LPH but below 6LPH, a pressure test warning is logged.
If the gas flow remains above 6LPH at the end of the pressure test, then the pressure test fails, a fault is logged and the BioTector stops.
Note:
1: In addition to the Pressure Test detailed above which operates once per day and each time the BioTector B3500ul is started, a Pressure Check is carried out as part of the Reactor Purge sequence. The Pressure Check only has pass /fail settings, it cannot generate any warning of a small leak in the BioTector B3500ul.
2: Pressure Tests are carried out at 400mbar, while the BioTector B3500ul runs typically at 4mbar, making the Pressure Tests a sensitive leak detection system.

43. Typical Pressure Test Menu.T 9 : 1 7 2 8 -
<  * I Z A C O M 6 s F N 4 . l / h L W 3 G B H
Two test modes are available:
Pressure Test: This simulates the pressure test in the same time as the BioTector allows (60s).
Pressurize Reactor: This simulate the pressure test with long time limit, useful for detecting a leak.

44. Mixer Reactor leaking through diaphragm?
PRESSURE TEST.
CO2 ANALYZER
ACID PUMP P3
DESTRUCTOR
OZONE
COOLER
OZONE GENERATOR
REACTOR
MIXER P2
BASE
ACID
SAMPLE
BYPASS
EXHAUST
MFC
OXYGEN
MODULE
AIR
BASE PUMP P4
SAMPLE PUMP P1
SAMPLE VALVE MV4
VALVE
MV1
MV3
O2 Pressure correct?
MFC reading correctly?
Air Pressure correct?
Pump
leaking?
Leak in component?
Fitting leaking?
Valve
Mixer Reactor leaking through diaphragm?
STREAM / MANUAL VALVES
STREAM 1
MANUAL
STREAM 2
As part of every Reactor Purge sequence, a Pressure Check is carried out, which detects a major leak in the analysis system. In addition, every time the BioTector B3500ul is started up and once per day thereafter, a separate Pressure Test is carried out. The Pressure Test has the facility to give an early warning of a small leak, and also can stop the BioTector B3500ul should major leak be detected.

45. PRESSURE TEST.
CO2 ANALYZER
ACID PUMP P3
DESTRUCTOR
OZONE
COOLER
OZONE GENERATOR
REACTOR
MIXER P2
BASE
ACID
SAMPLE
BYPASS
EXHAUST
MFC
OXYGEN
MODULE
AIR
BASE PUMP P4
SAMPLE PUMP P1
SAMPLE VALVE MV4
VALVE
MV1
MV3
3. Is the MFC reading correctly?
1. Is the air pressure correct?
2. Is the O2 pressure correct?
5. Disconnect tube over cooler.
Seal tube.
Test.
4. Disconnect tube at TEE.
6. Seal exhaust valve.
STREAM / MANUAL VALVES
STREAM 1
MANUAL
STREAM 2
Always follow a structured approach when looking for a leak.
CAUTION: Traces of chemicals may be in tubes when they are opened.

46. Flow Test Purpose: Frequency of activation: Operation: Note:
To detect a blockage or partial blockage in a gas flow path BioTector.
Frequency of activation:
Once per day, and when the BioTector B3500ul is started.
Operation:
The microcontroller activates the MFC with a gas flow of 60 LPH.
The gas flow through the exhaust and sample out valves / lines are tested independently.
If there is no blockage in either of the lines, and the BioTectors flow remains above 45 LPH, the flow test passes.
If the gas flow drops below 45 LPH but remains above 30LPH within the 30 second flow test time, a flow warning is logged.
If the gas flow drops below 30LPH, a flow fault is logged and the BioTector stops.
Note:
In addition to the Flow Test detailed above which operates once per day and each time the BioTector B3500ul is started, the gas flow is continuously monitored as the analyzer runs. If the flow falls below 50% of its set-point for >12 seconds, a fault is generated and the BioTector B3500ul stops.

47. Typical Flow Test Menu. Two modes available for each valve:T E S 9 : 1 7 2 8 -
<  * X H A U 3 M P 4 I s C N 6 . l / h 5 G R B
Two modes available for each valve:
Exhaust (or Sample Out) Test: Simulate the flow test in the same time as the BioTector allows (30s).
Exhaust (or Sample Out) Flow: Simulate the flow test with long time limit, useful for detecting a blockage.

48. Tube or fitting blocked? Tube blocked outside BioTector?
FLOW TEST: EXHAUST.
CO2 ANALYZER
ACID PUMP P3
DESTRUCTO R
OZONE
COOLER
OZONE GENERATOR
REACTOR
MIXER P2
BASE
ACID
SAMPLE
BYPASS
EXHAUST
MFC
OXYGEN
MODULE
AIR
BASE PUMP P4
SAMPLE PUMP P1
SAMPLE VALVE MV4
VALVE
MV1
MV3
MFC reading correctly?
Air pressure correct?
O2 pressure correct?
Reactor blocked?
Tube or fitting blocked?
Valve blocked?
Tube blocked outside BioTector?
STREAM / MANUAL VALVES
STREAM 1
MANUAL
STREAM 2
The gas flow is continuously monitored as the analyzer runs. If the flow falls below 50% of its set-point for >12 seconds, a fault is generated and the BioTector System-C stops.
In addition, every time the BioTector System-C is started up and once per day thereafter, a separate Flow Test is carried out. This test has the additional facility to give an early warning of a small leak.

49. FLOW TEST: EXHAUST.
CO2 ANALYZER
ACID PUMP P3
DESTRUCTO R
OZONE
COOLER
OZONE GENERATOR
REACTOR
MIXER P2
BASE
ACID
SAMPLE
BYPASS
EXHAUST
MFC
OXYGEN
MODULE
AIR
BASE PUMP P4
SAMPLE PUMP P1
SAMPLE VALVE MV4
VALVE
MV1
MV3
3. Is the MFC reading correctly?
1. Is the air pressure correct?
2. Is the O2 pressure correct?
5. Disconnect tube over cooler.
Test.
4. Disconnect tube at TEE.
6. Disconnect tube before ozone destructor.
7. Disconnect tube after ozone destructor.
8. Disconnect tube outside BioTector.
STREAM / MANUAL VALVES
STREAM 1
MANUAL
STREAM 2
Always follow a structured approach when looking for a blockage in a tube.
CAUTION: Traces of chemicals may be in tubes when they are opened.

50. Tube or fitting blocked? Tube blocked outside BioTector?
FLOW TEST: SAMPLE OUT.
CO2 ANALYZER
ACID PUMP P3
DESTRUCTOR
OZONE
COOLER
OZONE GENERATOR
REACTOR
MIXER P2
BASE
ACID
SAMPLE
BYPASS
EXHAUST
MFC
OXYGEN
MODULE
AIR
BASE PUMP P4
SAMPLE PUMP P1
SAMPLE VALVE MV4
VALVE
MV1
MV3
MFC reading correctly?
Air pressure correct?
O2 pressure correct?
Tube or fitting blocked?
Valve blocked?
Tube blocked outside BioTector?
STREAM / MANUAL VALVES
STREAM 1
MANUAL
STREAM 2
The gas flow is continuously monitored as the analyzer runs. If the flow falls below 50% of its set-point for >12 seconds, a fault is generated and the BioTector System-C stops.
In addition, every time the BioTector System-C is started up and once per day thereafter, a separate Flow Test is carried out. This test has the additional facility to give an early warning of a small leak.

51. FLOW TEST: SAMPLE OUT.
CO2 ANALYZER
ACID PUMP P3
DESTRUCTO R
OZONE
COOLER
OZONE GENERATOR
REACTOR
MIXER P2
BASE
ACID
SAMPLE
BYPASS
EXHAUST
MFC
OXYGEN
MODULE
AIR
BASE PUMP P4
SAMPLE PUMP P1
SAMPLE VALVE MV4
VALVE
MV1
MV3
3. Is the MFC reading correctly?
1. Is the air pressure correct?
2. Is the O2 pressure correct?
4. Disconnect tube at TEE.
Test.
5. Disconnect tube after valve. Test.
6. Disconnect tube after valve. Test.
STREAM / MANUAL VALVES
7. Disconnect tube outside BioTector. Test.
STREAM 1
MANUAL
STREAM 2
Always follow a structured approach when looking for a blockage in a tube.
CAUTION: Traces of chemicals may be in tubes when they are opened.

52. To check the 4-20ma signals and volt free contacts.
Confirm all signals (4-20mA and volt free contacts) are signaling correctly to the external control device. The actual signals used will depend on the site configuration.
The volt free contacts and 4-20ma signals are outlined below.

53. Service Counter
When the system service is completed, go to Diagnostics, Service menu and select RESET SERVICE COUNTER function.
Note that the SERVICE COUNTER function is a day counter which counts down from 200 days (about 6.5 months by default) and reminds the customer that the 6 monthly service is due.

54. Reagent Purge, DI Water analysis and Zero Calibration Procedure.
Reagent Purge, DI Water analysis and Zero Calibration procedure is used to:
Purge the reagent lines and pumps of old reagents, and fill them with new reagents.
Wash and pH neutralize the reactor.
Remove the organic contamination caused by the shipping and storage.
Perform a Zero Calibration on the BioTector B3500ul.
Phase 1: Purge the reagent lines and pumps of old reagents, and fill them with new reagents.
The acid and base pulse pumps run at the same time for a period of ~40 seconds. During this period, acid and base from the reagent containers fill the reagent lines, pumps and reactor. As the acid reagent is 1.5 times as strong as the base reagent, the pH of the reagent mix in the reactor is acidic, with a pH<1.
The reagents are then purged from the reactor.
This is repeated 4 times to ensure that all the old reagents are purged from the system.
The reactor mixer does not run during this phase.
Phase 2: Wash and pH neutralize the reactor.
The acid pump runs for 300 pulses, and the base pump for 450 pulses. As the acid reagent is 1.5 times as strong as the base reagent, the pH of the reagent mix in the reactor is neutral ~ pH7.
The Reactor Mixer runs for a period of 60 seconds, washing the reactor.
Phase 3: Connect DI Water and run 10 analysis cycles to remove TOC contamination introduced during service
Shipping and long storage can introduce TOC contamination which will affect the zero offset.
Connect DI Water or alternatively tap water to manual port and using Manual Program run 10 analysis cycles to remove the organic contamination. If the TOC results will not stabilize (±20ppb) run additional reactions using DIW.

55. Reagent Purge, DI Water analysis and Zero Calibration Procedure.
Phase 4: Perform a Zero Calibration on the BioTector B3500ul.
Zero calibration carried using reagents only (default)
Using the reagent configurations from the selected range a zero calibration is carried out by injecting the TIC acid into the reactor, followed by the base which is then oxidized, followed by the TOC acid.
The zero offset is calculated from the result.
To neutralize the fluid in the reactor, an appropriate volume of base is injected into the reactor which neutralizes the fluid in the reactor. Note, this is not required in the normal reaction, as the volume in the reactor is much larger due to the volume of liquid injected by the sample.
The above procedure is repeated for the programmed number of zero reactions, and the zero offset calculated from the results.
When this is complete, confirm that the zero readings are stable.
b) Zero calibration carried using ultra-pure water and reagents (optional)
Typically there could be up to 10ppb difference in the TOC background when Zero calibration is carried with ultra-pure water compared to reagents only. This function can be selected in the ZERO PROGRAM menu.
If the Zero Calibration is carried using ultra-pure water the TOC content in this water shouldn’t exceed 5ppb as high TOC content of the water can introduce significant error in the TOC measurement.

56. Purge of reagents.
OXYGEN
MODULE
MFC
CO2 ANALYZER
AIR
ACID PUMP P3
ACID
COOLER
OZONE GENERATOR
DESTRUCTOR
OZONE
BASE PUMP P4
BASE
SAMPLE PUMP P1
STREAM / MANUAL VALVES
EXHAUST
VALVE
MV1
REACTOR
MIXER P2
STREAM 1
STREAM 2
MANUAL
REACTOR
VALVE
MV3
SAMPLE
BYPASS
SAMPLE VALVE MV4
EXHAUST
The Acid and Base Pumps pulse and inject reagents into the reactor.
Built in limitations prevent the reactor from flooding.

57. Reactor purge, pressure check.
CO2 ANALYZER
ACID PUMP P3
DESTRUCTOR
OZONE
COOLER
OZONE GENERATOR
REACTOR
MIXER P2
BASE
ACID
SAMPLE
BYPASS
EXHAUST
MFC
OXYGEN
MODULE
AIR
BASE PUMP P4
SAMPLE PUMP P1
SAMPLE VALVE MV4
VALVE
MV1
MV3
STREAM / MANUAL VALVES
STREAM 1
MANUAL
STREAM 2
Both the Reactor Valve and the Exhaust Valve are closed. The MFC is programmed with a set-point (40l/h).
Oxygen gas starts to flow. As all outlets from the analysis system are closed, after ~15 seconds the oxygen flow will drop below the “Pressure Check Pass” setting.
If the flow does not drop, the BioTector B3500ul generates a fault “Pressure Check Fault” and shuts down.

58. Reactor purge, pressure release.
CO2 ANALYZER
ACID PUMP P3
DESTRUCTOR
OZONE
COOLER
OZONE GENERATOR
REACTOR
MIXER P2
BASE
ACID
SAMPLE
BYPASS
EXHAUST
MFC
OXYGEN
MODULE
AIR
BASE PUMP P4
SAMPLE PUMP P1
SAMPLE VALVE MV4
VALVE
MV1
MV3
STREAM / MANUAL VALVES
STREAM 1
MANUAL
STREAM 2
The Reactor Valve is opened, and the oxygen pressure in the Cooler and CO2 analyzer purge the sample from the reactor. The MFC is programmed with a new set-point (20 l/h).
If the gas flow cannot match the set-point, then it is assumed that there is a blockage in the Sample Valve or Bypass Line. In this case, the BioTector B3500ul generates a fault “Low O2 flow SO” and shuts down.

59. Hach TOC standards for B3500ul system (acidified with H2SO4)
Span Calibration Settings S P A N D J U T 9 : 1 7 2 8 -
< O C . 3 4 I 5 6 R L B H E K G M V m g / l
>
If a span calibration standard is available, program the concentration(s) of the standard solution(s) in the Span Calibration menu.
If a span calibration standard is not available, prepare a calibration standard solution at the necessary concentration. See procedures described in the manual or according to information sheet “R009. Standard Solutions for BioTector Multi-component Analyzer” TOC Standard solution for B3500ul analyzer cannot be acidified with Phosphoric acid as this could affect the pH, reduce the oxidation and introduce significant error in TOC measurement.
Connect the standard solution to the MANUAL/CALIBRATION port. If both of these ports are not available, use the SAMPLE 1 port, but first set the Sample Pump REVERSE time to 0 (zero) seconds in Sample Pump menu. It is recommended that the standard solution is located at the same height as the sample chamber or catch-pot.
Run the Span Calibration (or Span Check) cycle using the “RUN SPAN CALIBRATION (or RUN SPAN CHECK)” function in Span Calibration menu. A minimum of 5 span calibration reactions is recommended.
Hach TOC standards for B3500ul system (acidified with H2SO4)
KHP 5mgC/l ( ) - for calibration
KHP 1mgC/l ( ) – for validation

60. Service Zero
To ensure that the correct zero offset is applied and to eliminate any remaining TOC contamination from the analyzer, a Service Zero cycle should be initiated using the SET SERVICE ZERO function in the Service menu. When initiated, BioTector automatically runs a total of 10 zero calibration cycles during the following 500 online measurements and automatically adjusts the zero offset values to compensate for the removal of the contamination. It will therefore not be necessary to revisit the BioTector after the start-up or to repeat the Zero Calibration cycle manually. See Section Service in the User manual for further details.
If ultra-pure water is used during the Zero Calibration, ensure that container with at least 5 litres of water is connected to the analyzer. It is recommended to use a sealed container with CO2 absorber and HEPA air filter installed in line on the vent/breathing tube to prevent the contamination of the water.
10-KBS-009 HEPA filter, PCS-205 CO2 absorber,

61. B3500ul analyser start-up sequence during commissioning and PM.1
Sequence:
10 DIW reactions (point 1 on the chart) – removal of the main portion of TOC contamination,
Zero calibration (point 2 on the chart) – initial zero offset adjustment to minimalize error during span calibration
5ppm Span calibration (point 3 on the chart, outside scale) – calibration factor adjustment
Service Zero (points 4 on the chart) – final removal of remaining TOC contamination and background adjustment (total of 10 zero calibration cycles during the following 500 online measurements).
Inform the client that the analyser will automatically correct the background during approximately 48h and elevated result of 20-50ppb as the system expels contaminants.