Aquasense - USER MANUAL...Bran+Luebbe PowerMon Chapter 1 Introduction 7 The following types of...

USER MANUAL

Publication No.: MT5-13DE04

Date: Septemberh 2009

Read this manual carefully before installing the system and pay attention to the

safety information. BRAN+LUEBBE GmbH will accept no liability for damages

due to non-observance of this manual. Rights under the warranty may also be

forfeited.

Rights under the warranty will also be forfeited if spare parts are used which are

not supplied by BRAN+LUEBBE GmbH.

Information in this manual is subject to change without notice and does not rep-

resent a commitment on the part of BRAN+LUEBBE GmbH.

No part of this manual may be reproduced or transmitted in any form or by any

means, electronic or mechanical, without the prior written permission of

BRAN+LUEBBE GmbH.

Where manuals are translated into several languages, the German language text

is considered as the original.

© Copyright 2009, BRAN+LUEBBE GmbH, Norderstedt. All rights reserved.

Bran+Luebbe PowerMon Chapter 1 Introduction 1

LLIISSTT OOFF CCOONNTTEENNTTSS

LIST OF CONTENTS ....................................................................................... 1

LIST OF FIGURES........................................................................................... 3

1 INTRODUCTION........................................................................................ 5 1.1 Conventions used in this manual ........................................................................ 6 1.2 Bran+Luebbe training courses ............................................................................ 7

2 SAFETY INFORMATION......................................................................... 11 2.1 General safety information ................................................................................ 11 2.1.1 Intended use ..................................................................................................... 12 2.1.2 Sources of danger and behaviour in case of emergency.................................. 12 2.1.3 Workplace ......................................................................................................... 13 2.1.4 Operating personnel.......................................................................................... 14 2.2 Rules for handling reagents .............................................................................. 14 2.3 Marking of hazardous substances .................................................................... 15 2.3.1 Hazard symbols and descriptions ..................................................................... 15 2.3.2 R and S phrases ............................................................................................... 16 2.4 Disposal ............................................................................................................ 17 2.5 Safety data sheets and operating instructions .................................................. 17

3 DESCRIPTION OF THE UNIT ................................................................. 19 3.1 Overview ........................................................................................................... 19 3.2 PowerMon and PowerMon S analyser applications .......................................... 19 3.3 PowerMon Kolorimeter and Silikometer ............................................................ 20 3.4 PowerMon Ionometer and Natriometer ............................................................. 21 3.5 PowerMon Titrometer........................................................................................ 21 3.6 PowerMon S...................................................................................................... 22 3.6.1 PowerMon S Light ............................................................................................. 23 3.6.2 PowerMon S Resources ................................................................................... 23 3.6.3 PowerMon S TN/TP .......................................................................................... 23 3.7 Design of the PowerMon and PowerMon S ...................................................... 24 3.7.1 Analyser section................................................................................................ 24 3.7.2 Control section .................................................................................................. 29 3.7.3 Spectrometer module (PowerMon S only) ........................................................ 31 3.8 Single and multi-stream operation .................................................................... 31 3.9 Measured value output and unit alarms ............................................................ 32 3.10 Specifications .................................................................................................... 33

4 INSTALLATION....................................................................................... 35

2 Bran+Luebbe PowerMon

4.1 Overview ........................................................................................................... 35 4.2 Operating conditions ......................................................................................... 35 4.3 Installing the unit ............................................................................................... 36 4.3.1 Wall mounting ................................................................................................... 36 4.3.2 Electrical installation.......................................................................................... 40 4.3.3 Hose connections.............................................................................................. 41 4.4 Workplace design.............................................................................................. 45

5 COMMISSIONING AND DECOMMISSIONING....................................... 47 5.1 Overview ........................................................................................................... 47 5.2 Preparing the unit.............................................................................................. 47 5.3 Starting the measuring cycle............................................................................. 48 5.4 Decommissioning.............................................................................................. 50

6 USING THE OPERATING SOFTWARE.................................................. 51

7 CARE AND MAINTENANCE................................................................... 53 7.1 Overview ........................................................................................................... 53 7.2 Daily maintenance............................................................................................. 54 7.3 Weekly maintenance......................................................................................... 54 7.4 Quarterly maintenance...................................................................................... 54 7.5 Yearly maintenance .......................................................................................... 58 7.6 Maintenance report ........................................................................................... 58

8 FAULT FINDING ..................................................................................... 61 8.1 Overview ........................................................................................................... 61 8.2 Information on unit malfunctions ....................................................................... 62 8.2.1 General problems.............................................................................................. 62 8.2.2 Problems within the analyser ............................................................................ 63 8.2.3 Problems with the measured values ................................................................. 64 8.2.4 Problems with the calibration ............................................................................ 67

APPENDIX A INDEX..................................................................................... 1

APPENDIX B TECHNICAL DATA ................................................................ 1


LLIISSTT OOFF FFIIGGUURREESS

Fig. 2.1: Hazard symbols................................................................................................... 16 Fig. 3.1: PowerMon Kolorimeter in housing....................................................................... 25 Fig. 3.2: PowerMon S TN/TP analyser .............................................................................. 26 Fig. 3.3: PowerMon photometer ........................................................................................ 27 Fig. 3.4: PowerMon S photometer..................................................................................... 27 Fig. 3.5: PowerMon measuring cells ................................................................................. 28 Fig. 3.6: Design of control section (single-stream unit) without cover ............................... 30 Fig. 4.1: Dimensional arrangement drawing PowerMon in housing and reagent cabinet . 37 Fig. 4.2: Dimensional arrangement drawing PowerMon in mounting frame...................... 38 Fig. 4.3: Dimensional arrangement drawing PowerMon S in housing and two reagent

cabinets ............................................................................................................... 39 Fig. 4.4: Pressure reducing valves (for 6 measuring points) ............................................. 42 Fig. 4.5: Arrangement drawing of single-channel peristaltic pump.................................... 44 Fig. 4.6: Arrangement drawing of 2-channel peristaltic pump ........................................... 44 Fig. 4.7: Arrangement drawing of 4-channel peristaltic pump ........................................... 45


11 IINNTTRROODDUUCCTTIIOONN

The Bran+Luebbe analysers belong to a new generation of modern, fully automatic online analysers. They measure trace concentrations of dissolved substances in liq-uids with the help of wet chemical and spectrascopic methods. The manual describes the following analysers:

• PowerMon Kolorimeter

• PowerMon Silikometer

• PowerMon Ionometer

• PowerMon Natriometer

• PowerMon Titrometer

• PowerMon S

This manual provides you with the necessary instructions for installing, commission-ing and decommissioning and maintaining your PowerMon and PowerMon S. We as-sume that operators have a basic technical knowledge. The operation of the unit us-ing the operating software is described in a separate manual "PowerMon - Operating Manual Operating Software" and "PowerMon S - Operating Manual Operating Soft-ware" respectively.

Read this manual carefully before installing and commissioning the system. The manual must be kept close to the unit and be available at all times.


The manual is divided into the following chapters:

CHAPTER 1 INTRODUCTION

CHAPTER 2 SAFETY INFORMATION

CHAPTER 3 DESCRIPTION OF THE UNIT

CHAPTER 4 INSTALLATION

CHAPTER 5 COMMISSIONING AND DECOMMISSIONING

CHAPTER 6 USING THE OPERATING SOFTWARE

CHAPTER 7 CARE AND MAINTENANCE

CHAPTER 8 FAULT FINDING

APPENDIX A INDEX

APPENDIX B TECHNICAL DATA

If you have any questions or if problems occur, you can contact our customer service hotline at any time:

HOTLINE TELEPHONE: ++49 (0)40/52202-505

HOTLINE FAX: ++49 (0)40/52202-592

If commissioning and/or the supply of reagents has been agreed, these ser-vices can be redeemed against a voucher which is sent by Bran+Luebbe to the initial customer (e.g. project engineering office or OEM).

1.1 Conventions used in this manual

The following designations are used:

• Capital letters are used to indicate operating modes and functions, e.g. CALIBRATION.

• Bold letters are used to indicate the keys on the touch screen.


The following types of safety information are used:

Danger: Used when non-observance could result in serious injury or death.

Warning: Used when non-observance could result in minor injuries or serious material damage.

Caution: Used when non-observance could result in minor material damage.

The information arrow is used for additional information or recommendations which relate to practical use of the equipment and which are important for trouble-free operation.

1.2 Bran+Luebbe training courses

Bran+Luebbe regularly offers practice-oriented training courses for all PowerMon and PowerMon S analysers.

Contents of the normally two or three-day-long training courses are:

• Introduction to analytical measuring methods

• Handling chemicals

• Operation of the equipment with practical exercises

• Maintenance work

• Fault finding on the equipment

You can obtain more information by telephone on: ++49 (0)40/522 02 505

Or send the following form to:

Bran+Luebbe GmbH

- Service AOLM -

Postfach 1360

22803 Norderstedt

You can also send an e-mail to the following address:

[email protected]

mailto:[email protected]

Bran+Luebbe PowerMon training

Bran+Luebbe GmbH, Service AOLM, Postfach 1360, 22803 Norderstedt

Yes, I would like to receive more information about the PowerMon/PowerMon S training courses.

We use a

PowerMon Ionometer/Natriometer

PowerMon Kolorimeter/Silikometer

PowerMon Titrometer

PowerMon S

Company

Name

Department

Street

Postcode/Location

Phone

Fax

E-mail

Bran+Luebbe PowerMon Chapter 2 Safety information 11

22 SSAAFFEETTYY IINNFFOORRMMAATTIIOONN

This unit may only be used for the purpose for which it is intended. The owner must ensure that the unit is only operated by technically suitable and trained personnel. The safety information must be observed.

2.1 General safety information

Danger: This unit contains electrical circuits, devices and modules operating under dangerously high voltages. Contact with these components may result in electric shock and severe or fatal injury.

Observe the following general precautions:

• All connection, maintenance and repair work which requires the control section to be opened may only be performed by a qualified electrician.

• Ensure that the protective conductor for the unit is connected.

• Check the mains cable for damage before commissioning. Do not switch on the unit if there is any damage to the mains cable or if the mains cable is worn.

• Switch the unit off before starting maintenance, repair or cleaning work in the control and analyser section. Make sure there is no liquid in the hoses.

• Switch the unit off before starting work on heated parts of the unit, as otherwise there is a risk of burning. The heating elements could also burn out.

• The control section of the unit contains capacitors which are charged to danger-ously high voltages. Wait at least one minute after switching the unit off before opening the control section.

• Never spray or wash down the unit, as no water may enter the interior.

• Protect the unit from unidirectional heat radiation, direct sunlight and vibration. It must be installed in a dry, dust-free room. Additional protective measures are re-quired in environments with corrosive gases and vapours or where there is the risk of explosion.

• Do not place or lay objects on top of the unit.


2.1.1 Intended use

The PowerMon and PowerMon S analysers are used for the on-line measurement of substances in aqueous solution. Depending on the method applied, the aqueous sample can be tested for the content of one or more exactly determined parameters which are specified in Appendix B. The units may only be used for this purpose. The units are intended for commercial use and are only permitted for this usage.

The units may not

• be operated under pressure, i.e. the sample to be analysed must be supplied un-pressurised.

• be used with other reagents than those described in the method description in Appendix B, or

• modified without permission. Any liability on the part of the manufacturer/supplier for damage resulting from unauthorised modifications shall be excluded.

2.1.2 Sources of danger and behaviour in case of emergency

The Bran+Luebbe PowerMon und PowerMon S units comply with the statutory safety requirements.

The hazards emanating from the units have been minimised by engineering design. Residual risks (electrical, mechanical, thermal, chemical or biological dangers) due to transport, installation, service and maintenance work or in operation cannot be com-pletely excluded however.

IMPORTANT! Be sure to observe the warning and safety information on the units and in this user manual.

In case of emergency it must be possible to shut down the unit immediately. An emergency exists whenever human life is endangered and/or other general risks are present. The source of danger may be the unit itself or it may have some other origin.


To switch off the unit in case of emergency pull out the mains plug. Free access to the mains plug must therefore be ensured at all times. If this is not possible, an emer-gency stop switch must be provided in the vicinity of the unit.

IMPORTANT! An emergency stop switch is not included with the PowerMon or PowerMon Sas standard.

• Rectify the fault.

• In case of fire use only appropriate extinguishing media.

• Warn the other staff of any danger, even if it is only suspected.

• Keep calm.

• After an emergency the unit may only be restarted when the fault has been recti-fied and it has been ensured that the unit has not been damaged.

2.1.3 Workplace

When operating the unit or carrying out service and maintenance work, the area around the unit and the unit itself must be looked upon as a workplace.

Reagents, some of which require to be marked in accordance with the Hazardous Substances Ordinance, are needed to operate the units. The operator must ensure that operating manuals specific to the equipment and to the material in accordance with the EU directives, and the necessary safety devices are provided in the vicinity of the workplace. If the system is installed without a housing, it must also be ensured that working areas below the unit are protected from dripping reagents.

IMPORTANT! Refer also to the information under 4 Installation, in particular 4.4 Workplace design.


2.1.4 Operating personnel

Only persons that are authorised and instructed by the user may work on the unit. Trainees may only work on the unit under supervision. The operator is responsible for third parties in the working area.

The user must

• make this user manual, the operating manual for the operating software, and the operating instructions specific to the units and to the material accessible to the operator, and

• satisfy himself that the operator has read and understand these manuals.

All persons who, as a result of their specialist training and experience, have sufficient knowledge to fulfil the requirements for operating this unit, are regarded as compe-tent, trained and qualified operating personnel. Furthermore, these persons must be familiar with the generally acknowledged rules of technology as well as the appropri-ate industrial safety and accident prevention regulations. This applies also and in par-ticular to the rules for the handling of reagents. This is addressed separately in the two chapters 2.2 Rules for handling reagents and 2.3 Marking of hazardous sub-stances.

Bran+Luebbe offers practical training courses for all PowerMon and Power-Mon S analysers, see also 1.2 Bran+Luebbe training.

2.2 Rules for handling reagents

Danger: The handling of reagents requires special safety procedures. This relates both to changing reagents and also to the rectification of leaks. Some re-agents are hazardous substances and can cause chemical burns, damage to health and may even result in death if swallowed. In the case of hazardous reagents, hazard symbols and R and S phrases will be found on the reagent containers. The applicable R and S phrases are also noted on the safety data sheets which are available for any hazardous reagent on request. In Section 2.3.1, you will find a list of hazard symbols, and in Section 2.3.2 a list of the R phrases (information relating to special risks) and the S phrases (safety advice).


Additionally pay attention to the following:

• Operating manuals specific to the unit and to the material as defined by the EU directives must be provided by the unit. The operator must inform himself with re-gard to the content of the operating manuals before starting work on the unit.

• Only specialist staff may work with reagents.

• Prevent any chemicals coming into contact with skin or mucous membranes.

• Wear protective clothing, gloves and safety glasses if necessary. Detailed infor-mation will be found in the operating manuals specific to the unit and to the mate-rial.

• Never pipette reagents by mouth.

• Do not put reagents into containers which due to their appearance and shape could be confused with those used for drinks.

• Do not eat, drink or smoke next to reagents.

• Remove splashes on and inside the unit immediately with a damp cloth.

• Keep reagents well sealed and in a safe place in order to prevent misuse.

2.3 Marking of hazardous substances

Some of the reagents used for the PowerMon and PowerMon S applications are haz-ardous substances. These reagents are subject to the regulations of the Hazardous Substances Ordinance (GefStoffV) in accordance with European law which contains the appropriate European ordinances that have been implemented.

Hazardous substances are substances or mixtures of substances which can be injuri-ous to human health. These may be solid, liquid or gaseous and can enter the human body by inhalation, swallowing or by contact with the skin.

If the reagents used with your analyser are classed as hazardous substances, they will be marked as follows:

• Hazard symbols. You will find an explanation of these in Section 2.3.1.

• The relevant R and S phrases (safety and hazard information). You will find a complete list of the R and S phrases in Section 2.3.2.

2.3.1 Hazard symbols and descriptions

The following hazard symbols and danger labels can be found on Bran+Luebbe re-agent containers:


Fig. 2.1: Hazard symbols

The danger labels have the following meaning:

Danger label Hazard F+ Extremely flammable F Highly flammable O Oxidising T+ Very toxic T Toxic Xn Harmful C Corrosive Xi Irritant N Environmentally harmful E Explosive

2.3.2 R and S phrases

Along with the hazard symbol, the hazard information (R phrases) and the safety in-formation (S phrases) give more detailed information on the characteristics of the hazardous substance. The phrases applicable to a Bran+Luebbe reagent are printed in words on the reagent container in each case. The R and S phrases are likewise listed in the safety data sheets (see 2.5).

The R phrases contain information relating to special hazards; the S phrases contain safety advice.


2.4 Disposal

Anybody who works with chemicals is obliged to dispose of them. Acids and bases may be poured into the waste water system after they have been neutralised. Toxic substances, heavy metals, solvents etc. must be disposed of in special incinerators or by recycling companies. In special cases, more detailed information can be found in the safety data sheets (see 2.5) or the instructions for use specific to the material.

If you have any problems with disposal or if you are unsure of anything, you can ob-tain assistance from Bran+Luebbe customer service.

If a unit is disposed of by the user, he is responsible for ensuring that this is carried out properly and in compliance with the applicable regulations.

2.5 Safety data sheets and operating instructions

A safety data sheet is available for every Bran+Luebbe reagent. If the data sheet was not supplied with the reagent, you can request it from Bran+Luebbe. It contains the following information:

• Chemical characteristics of the substance or substance mixture

• Physical and safety-related data

• Transport codes

• General specifications

• Protective measures, storage, handling and disposal

• What to do in case of accident or fire

• Toxicology data

• Environmental data

According to applicable EU Directives, the employer must also provide information to his employees with the help of operating instructions. These operating instructions should clarify the hazards in the workplace due to reagents as briefly and clearly as possible. They contain information such as

• Hazardous substance designation

• Risks for human beings and the environment

• Protective measures and behavioural rules

• What to do in an emergency

• First aid measures

• Proper disposal

Bran+Luebbe PowerMon Chapter 3 Description of the unit 19

33 DDEESSCCRRIIPPTTIIOONN OOFF TTHHEE UUNNIITT

3.1 Overview

This chapter contains information about

• General PowerMon and PowerMon S analyser applications (Section 3.2)

• PowerMon Kolorimeter/Silikometer (Section 3.3)

• PowerMon Ionometer/Natriometer (Section 3.4)

• PowerMon Titrometer (Section 3.5)

• PowerMon S (Section 3.6)

• PowerMon and PowerMon S design (Section 3.7)

• Single-stream and multi-stream operation options (Section 3.8)

• Measured value output (Section 3.9)

• Specifications (Sections 3.10)

3.2 PowerMon and PowerMon S analyser applications

PowerMon and PowerMon S analysers belong to the Bran+Luebbe on-line monitor product group.

All PowerMon and PowerMon S analysers operate fully automatically using wet-chemical or spectroscopic methods. They measure on-line trace concentrations of dif-ferent parameters in liquids, e.g. phosphate, nitrate, ammonia, chlorine, metals and silica. Application areas include power generation, water treatment, chemical process engineering, chemical surface treatment and waste water technology.


Different measuring methods are required depending on which parameters are to be investigated. Bran+Luebbe has developed the following types of unit to meet the dif-ferent requirements:

Bran+Luebbe PowerMon Kolorimeter

Bran+Luebbe PowerMon Silikometer

Bran+Luebbe PowerMon Ionometer

Bran+Luebbe PowerMon Natriometer

Bran+Luebbe PowerMon Titrometer

Bran+Luebbe PowerMon S Light

Bran+Luebbe PowerMon S Resources

Bran+Luebbe PowerMon S TN/TP

3.3 PowerMon Kolorimeter and Silikometer

The Kolorimeter is a unit for the photometric measurement of substances dissolved in water. Among other things, it is used for measuring phosphate in municipal or indus-trial waste water.

From the design point of view, the Silikometer is a Kolorimeter that is used especially for the analysis of silica.

The unit is permanently connected to the process to be analysed by means of sam-pling lines. The operation of the unit is cyclic.

Sample and reagents are mixed by peristaltic pumps in an exactly defined ratio with the help of a mixing device and placed in a vessel or helix to react. The reagents are chosen so that they form a coloured compound with the component to be measured. The intensity of the colour depends on the concentration of the component to be measured.

At the end of the reaction period the coloured solution is irradiated with monochro-matic light in the photometer and the extinction measured, i.e. the attenuation of the light due to the coloration of the solution. The required concentration of the compo-nent to be measured is then calculated from the extinction.


3.4 PowerMon Ionometer and Natriometer

The Ionometer is a device for the potentiometric measurement of a substance dis-solved in water. Ion concentrations are measured with the help of ion-selective elec-trodes. It is used among other things for monitoring ammonium in waste water.

From the design point of view, the Natriometer is an Ionometer which, however, is used especially for the measurement of sodium.

The Ionometer is permanently connected to the process to be analysed by means of sampling lines. Sample and reagents are mixed by peristaltic pumps in an exactly de-fined ratio with the help of a mixing device. The reagents cause a stabilisation of the ion concentration and prevent interfering components from having an effect.

Sample and reagents pass into the measuring cell which contains a single-rod meas-uring chain or separate measurement and reference electrodes. In the measuring cell the ions of the component to be measured generate a potential at the ion-selective electrode which can be measured. This voltage is proportional to the logarithm of the concentration of the component to be measured.

3.5 PowerMon Titrometer

The Titrometer is a device for the volumetric measurement of a substance dissolved in water. With this unit, the concentration of e.g. free acid, free alkali, hardness, met-als or the acid and base capacity can be measured by dosage of a suitable titrant.

The unit is permanently connected to the process to be analysed by means of sam-pling lines. The operation of the unit is cyclic.

Within a fixed programme sequence, the system is drained and rinsed, the sample added, if necessary mixed with diluting water and an additional reagent, and the ti-trant added. This all takes place in the titration vessel. Detection is by means of elec-trodes, which are immersed in the titration vessel and measure a voltage which varies with the titration.

Measuring principle of potentiometric titration

During titration, a titrant with a known concentration, which reacts with the substance to be detected, is added to an exactly metered amount of sample. Titrant is added un-til a measurable transition point is reached, which represents the end point of the titra-tion (indication point).

In potentiometric titration, the indication point is determined with the help of elec-trodes which continuously measure potential changes in the solution. The potential changes come about by the fact that the ion concentrations in the solution change when the titrant is added.


Specific features of voltametric titration

In voltametric titration, a constant current of a few microamperes is applied to the measuring circuit consisting of measuring electrode and reference electrode. The amount of titrant added is measured. In this case, it is the polarisation voltage which changes suddenly at the end of the titration. At the indication point, the amount of ti-trant added is exactly the same as the amount of substance to be detected in the sample.

The concentration of the substance to be detected in the sample solution can now be calculated from the volume of the added titrant and its concentration. This is based on the number of titration steps, which is directly proportional to the metered volume. The precise concentration of the titrant does not need to be known if the concentra-tion of the calibration solution(s) is known.

3.6 PowerMon S

The PowerMon S is a multi-parameter on-line analyser, which can measure several parameters in one unit. Determination is based on a spectrometric measurement in the UV/VIS range (200 – 710 nm).

The PowerMon S is permanently connected to the process to be analysed by means of sampling lines. In the unit, the sample is fed directly or following an auxiliary chemical reaction to a flow cell in which it is irradiated with UV/VIS light. Depending on the composition of the sample, light at different wavelengths is absorbed to differ-ent degrees, which is recorded by the integral diode array spectrometer. With the help of previously performed base calibrations, certain wavelengths are selected from the measured sample spectra and the measurements for the parameters to be detected are calculated by means of the appropriate extinction. The extinctions of several wavelengths are used for the calculation, particularly in the case of measuring pa-rameters which are accessible by direct spectroscopy.

The sequence is controlled by sequence programmes, which have been produced for the individual sub-tasks of the analysis cycle and which switch the valves and pumps, initiate flash lamp measurements and calculate the measured values. A programme sequence is defined for these programmes, which controls the order of the different programmes. These programmes are partially nested, i.e. they overlap one another in time, so that a new sample can be fed into the system, for example, while the previ-ous sample is still reacting in the UV decomposition unit.

In addition to the programme sequence, which is processed linearly, programmes can also be called at defined intervals by means of a timer. This occurs, for example, in the case of calibration programmes in which the base calibrations are adjusted. In this case, the entire programme sequence is first processed to the end and the requested programme is then started.

Programmes can also be started manually, e.g. flushing programmes. In this case, the entire programme sequence is first processed to the end and the manually re-quested programme is then executed once.


3.6.1 PowerMon S Light

From the design point of view, the PowerMon S Light is the simplest of the Power-Mon S family. The unit is designed for determining parameters which are accessible by direct spectroscopy such as nitrate, the SAC or organic compounds, where no auxiliary chemical reactions are required for their determination.

3.6.2 PowerMon S Resources

As well as measurement by direct spectroscopy, the PowerMon S Resources also provides the option of incorporating up to 3 chemical colour reactions for measure-ments. For this purpose, sample and reagents are mixed by peristaltic pumps in an exactly defined ratio with the help of a mixing device and placed in a vessel or helix to react. The reagents are chosen so that they form a coloured compound with the com-ponent to be measured. The intensity of the colour depends on the concentration of the component to be measured.

A typical application for the PowerMon S Resources in the sewage treatment area is the determination of the following parameters, which can be detected with a single unit:

• Ammonium

• Ortho phosphate

• Nitrate

• SAC (Spectral Absorption Coefficient according to DIN 38404, Part 3)

Nitrate and SAC are measured by direct spectrometry, i.e. the sample is fed directly into the flow cell. Phosphate and ammonium on the other hand do not absorb or ab-sorb only weakly in the UV/VIS range and are measured by means of auxiliary chemical reactions.

Possible sampling points range from the treatment plant infeed via the aeration tank to the discharge. The PowerMon S Resources is suitable for process optimisation as well as for monitoring the discharge concentration.

3.6.3 PowerMon S TN/TP

A special application is the PowerMon S TN/TP (total nitrogen/total phosphorus, which is likewise used in the sewage treatment area and for the analysis of surface and waste water). This unit is specially designed for determining the two parameters nitrogen and phosphorus. It contains a UV decomposition unit for the combined ther-mal UV decomposition of phosphorus and nitrogen compounds.


3.7 Design of the PowerMon and PowerMon S

Each PowerMon and PowerMon S consists of a mounting panel (analyser section) which contains all the necessary measuring components. The analyser is wall-mounted in a housing or in a rack (only possible with PowerMon).

• Analyser section The analyser section contains the elements necessary for the measuring proc-ess. The chemical reaction and the measurement of the analysis values take place here. Furthermore the analyser section contains a touch screen for the dis-play of measured values and messages, and for inputting data.

The components of the analyser are mounted on a pivotable mounting plate.

• Control section The control section is located at the rear of the pivotable plate. It is protected by an additional housing in which the microprocessor, the terminal strips, the power supply etc. are located. The control section controls the pumps and valves, evaluates the results and communicates with the operating personnel or a super-imposed control computer.

• Spectrometer module ( PowerMon S only) The spectrometer module is located in the top part of the housing. It contains the spectrometer electronics.

These units are described in more detail below.

3.7.1 Analyser section

All the main parts for wet-chemical detection are located in the analyser section. These include pumps, valves, low-sample switch and the photometer or measuring cell. Fig. 3.1 shows an example of the analyser section in a Kolorimeter. The figure shows a multi-stream unit. Depending on the application, further elements, such as reductors, heating elements or mixers, can be added in the individual case. The num-ber of peristaltic pumps and valves varies depending on the number of measuring points and the application.

The information for your specific unit is shown in the equipment diagram and the hose diagram of the Method Description in Appendix B.

The equipment diagram shows the positions of the components used in the unit (e.g. pumps, valves). All possible components that are important for the analysis process are shown. Those used in your specific unit can be seen from the table below the diagram.

The hose diagram shows details of the analyser construction with materials, type of sleeve joints, dimensions, diameters and the arrangement of the hoses.


The figures below show a PowerMon Kolorimeter and a PowerMon S TN/TP.

1. Photometer 2. Touch screen 3. Peristaltic pump 4. Sample valves

5. Low-sample detector 6. Drain valve 7. USB Interface 8. Reaction oven

1

6

3

4 5

27

8

Fig. 3.1: PowerMon Kolorimeter in housing


1. Photometer 2. Touch screen 3. Peristaltic pump 4. Sample valves

5. Low-sample detector 6. Drain valve 7. USB Interface 8. UV digester

72

18

3

6

5

4

Fig. 3.2: PowerMon S TN/TP analyser

The analyser normally consists of following components:

• Photometer (see Fig. 3.3 and Fig. 3.4) In the photometer the light absorption of the sample solution is measured after the reaction and the formation of the colour complex. The concentration of the component to be measured is then calculated from this value (Kolorimeter, Silikometer and PowerMon S only). The photometer of the PowerMon S is con-nected to the Spektrometer module by means of fibre-optic cables.


1. LED 2. Condenser 3. Beam splitter

4. Flow cell 5. Measuring-side detector (refer-

ence side is hidden)

1

2 35

4

Fig. 3.3: PowerMon photometer

1. Fibre-optic cable coupling 2. Diffuser and condenser

3. Flow cell 4. Focusing

2 3 4

1 1

Fig. 3.4: PowerMon S photometer

• Measuring cell (see Fig. 3.5) Different types of measuring cell are used depending on the measuring principle and the component to be measured (Ionometer and Titrometer only).

Either a single-rod measuring chain or a measuring electrode and a reference electrode are immersed in the measuring cell.

With the Ionometer/Natriometer, the ions of the component to be measured gen-erate a measurable voltage which is proportional to the logarithm of the concen-tration. The temperature of the measuring cell is controlled by a heating element.

With the Titrometer, the titration takes place in the measuring cell. Reagents and sample are mixed in the measuring cell and the titrant is added. The electrodes measure the potential of the solution during the titration.

Depending on the application, other components may be present, e.g. heating elements, reductors or similar. A magnetic stirrer with magnetic mixing rods in the measuring cell ensures that the temperature of the measuring cell is controlled


evenly and that the solution to be titrated is mixed uniformly (Ionometer, Na-triometer and Titrometer only).

1. Ionometer meas-

uring cell 2. Natriometer

measuring cell 3. Titrometer meas-

uring cell

Fig. 3.5: PowerMon measuring cells

• Peristaltic pumps Peristaltic pumps are used to meter the sample, reagents and calibration solu-tions. These pumps consist of a speed-controlled motor with gearbox, rotor, hose bed and metering hose (see Fig. 4.5). They are triggered by the sequence pro-grammes stored in the unit. Different metering volumes are realised by the choice of metering hose and pump speed.

• Solenoid valves Solenoid valves are used to switch between different sample streams, calibration solutions, etc. They are triggered by the sequence programmes stored in the unit.

• Reaction oven (see Fig. 3.1) In some applications, a reaction oven is used to increase the speed of the reac-tion. This can also be used to pre-heat the sample and to assist the UV decom-position.


Danger: The reaction oven may contain hot and aggressive liquids. Before start-ing any maintenance work, make sure that the reaction oven has cooled down, has been emptied and the unit is switched off.

• UV digester (see Fig. 3.2) UV digesters are used for applications that require decomposition of the sample. Depending on the application, the sample is irradiated with UV-light of different intensity as it flows through the system or in batches.

Danger: Be sure to switch the unit off before starting maintenance work on the UVdigester. Otherwise hazardous UV radiation may escape which could lead to irreparable eye damage. The UV digester may also contain hot and aggressive liquids. Before starting any maintenance work, make sure that the reaction oven has cooled down and has been emptied.

• Low-sample switch and if applicable low-diluting-water switch A low-sample or a low-diluting-water switch monitors whether there is sufficient sample or diluting water available to the unit.

These sensors are optoelectrical elements which detect the presence of liquids within the feed tubes at specific times. If an adjustable threshold value is ex-ceeded in a certain time interval, the switch responds. If a shortage occurs, the unit outputs an appropriate error message. The response sensitivity can be ad-justed by means of the integral potentiometer. The instantaneous status is indi-cated by an LED.

• Low-reagent switch (option) Up to 5 reagent flows can be monitored as an option. The principle of operation is similar to that of the low-sample switch.

• Containers for reagents and calibration solutions Reagent and calibration solutions are kept in storage containers which are con-nected to the respective pumps and valves by means of extraction pipes. As an option, a reagent cabinet, which is capable of holding up to 6 reagent containers (container size: 5 l), can be located below the unit housing. If, in rare cases, more than 6 reagents are required, a second reagent cabinet can be placed under-neath the unit housing. In this case, it must be ensured that calibration solutions are placed in the top reagent cabinet.

3.7.2 Control section

The control section contains all components which are necessary for controlling the analyser and for signal generation and processing.


It is located at the rear of the pivotable analyser plate and is provided with an addi-tional housing for protection against the penetration of moisture.

Fig. 3.6 shows the control section and its components with the cover removed.

Danger: The control section contains electrical circuits, devices and assemblies oper-ating under dangerously high voltages. Contact with these components may result in electric shock and severe or fatal injury.

The control section may only be opened by a qualified electrician. The unit must be switched off before opening.

Fig. 3.6: Design of control section (single-stream unit) without cover

You will find details of the wiring in the terminal diagram and the circuit diagrams in Appendix B. Depending on the configuration of the unit, boards other than those shown in Fig. 3.6 may be found in the control section.

The analyser is controlled and monitored by a microprocessor based on a PC104. The tasks of this integrated microprocessor are:

• Control of the analysis programme

• Measurement processing


• Measurement display (conversion of data to be displayed on the touch screen and for outputting to the analogue current output)

• Management of the sample flow control

• Data exchange with higher-level data processing systems

• Automatic fault monitoring

• Dialogue with the operating staff and/or a superimposed control computer

All data, reports and sequence programmes as well as the unit configuration are stored on a compact flash card.

The analysis cycle is factory-programmed by Bran+Luebbe. Changes by the user are therefore not usually necessary. The exact sequence programme for your unit will be found in the method description in Appendix B.

All important parameters such as limit values, calibration data, temperatures, etc. can be entered, changed or deleted via the touch screen. Depending on the relevance, some areas are protected by a password.

3.7.3 Spectrometer module (PowerMon S only)

All the electronic components for the spectrometer are located in the spectrometer module. These include the high-voltage power supply, the Xenon flash lamp, the di-ode array module and the read-out electronics.

For a spectrometric measurement, the light from the Xenon flash lamp is guided to the photometer by means of a fibre-optic cable. The optical system here homoge-nises the light beam before it is fed through the flow cell in which the solution to be measured is located. The light beam is fed back to the spectrometer module by means of a further fibre-optic cable. Here, the beam is diffracted by a grid in the diode array module. The light, which is now diffracted according to wavelength, impinges on an array with 256 photodiodes, where each diode is assigned to particular wave-lengths. In this way, a complete spectrum from 200 to 710 nm is recorded.

3.8 Single and multi-stream operation

The PowerMon and PowerMon S are equipped with one measuring point as stan-dard. As an option, they can be expanded to up to 6 measuring points.

The order in which the samples of the individual measuring points is analysed is de-fined in the operating software. This order can be adapted at any time to suit chang-ing requirements. If one sample stream fails, the measurement is automatically con-tinued with the next measuring point.


Depending on the parameters entered, in multi-stream operation either a particular measurement from a selected measuring point is displayed, or the display shows the current results of the analysis of all measuring points alternately every 5 seconds.

3.9 Measured value output and unit alarms

You can display the measured values in various different ways.

• Display on the touch screen When the unit is in MEASURING mode, the most recent measurement is shown on the touch screen (refer to the user software operating manual for the operat-ing modes).

You have a choice of two display modes:

rolling : With the rolling display, the current most recent measurements from the individual measuring points are displayed one after the other. They change automatically after 5 s.

single : With the single display, on the other hand, the current most recent measurement from a particular measuring point is displayed.

The display mode can be changed by means of the appropriate button on the touch screen at any time.

• Display in the control room The measured values can also be transmitted to a central control room by means of analogue signal outputs (mA current outputs) where they can be displayed.

Digital signals are also provided, for example for a general alarm and limit value alarms. You will find details of the connections in Section 4 and in the terminal and circuit diagrams in Appendix B.

• Call via Ethernet The PowerMon and PowerMon S have an Ethernet interface as standard which enables the unit to be connected to the local network or to the Internet. The unit works with TCP/IP.

• Storage via USB connector Data from the unit can be stored automatically on a USB flash drive via the USB connector and processed elsewhere. A directory called "Database" must be pre-sent on the USB flash drive. Additional software, which is available free of charge from Bran+Luebbe, is required to transfer the PowerMon database to a PC or to a .CSV-file.


3.10 Specifications

The technical data for the unit is listed below. Possible deviations are noted in Ap-pendix B. No. of measuring points: 1 – 2 (with optional sample upgrading up to 6)

Cycle time: Kolorimeter/Silikometer/Ionometer: typical 6 - 15 min Titrometer: variable PowerMon S: variable

Signal output:

0/4...20 mA, zero selectable, maximum burden 500 Ω, gal-vanically isolated, test voltage 1000 V AC (2 outputs on main board, 4 further outputs on expansion board, additional out-puts possible via external CAN Bus modules)

Limit alarm signal: Voltage-free normally open contacts:

3 voltage-free normally open contacts are provided (with op-tional expansion up to 11), max. load: 30 V DC 6 A; 60 V DC 0.6 A; 110 V DC 0.2 A; 250 V AC 6 A

General alarm (unit fault): Voltage-free normally open contact, max. load: 30 V DC 6 A; 60 V DC 0.6 A; 110 V DC 0.2 A; 250 V AC 6 A Sample quantity: Min. 1 - 3 l/h (depending on application), particle-free Max. sample feed pressure Unpressurised Sample temperature: with sample heating (op-tion):

15 – 45 °C (288 - 318 K) 1 – 45 °C (274 – 318 K)

Connection: Flexible hose (PVC, PVDC, Viton, etc.) ID 1.5 - 3 mm Waste outlet: Unpressurised, flexible PVC hose ID 10 mm Ambient temperature: 15 - 35°C (288 - 308 K); even less with sample heating

Rated voltages: 85 ... 264 VAC at 47 ... 63 Hz 120 ... 370 VDC Mains connection: Earthed socket with 3 m cable (as supplied) Power requirement: Max. 150 VA

Protection: IP 54 (with housing only) IP 65 (optional) Device class: Class A (according to DIN EN 61326:2004)

Interfaces:

USB : For data download and software update LAN : Network connection Modem : Optional CAN Bus : For connection of external sensors

Dimensions: In frame with housing: with reagent cabinet

PowerMon 780 x 625 x 150 mm 700 x 600 x 320 mm 1100 x 600 x 354 mm

PowerMon S Not possible 790 x 600 x 320 1190 x 600 x 354

Weight: In frame with housing with reagent cabinet

PowerMon 18 – 25 kg 37 – 44 kg 53 – 60 kg without reagents (depending on application and number of measuring points)

PowerMon S Not possible 39 – 49 kg 55 – 65 kg without reagents (depending on application and number of measuring points)

Bran+Luebbe PowerMon Chapter 4 Installation 35

44 IINNSSTTAALLLLAATTIIOONN

4.1 Overview

This chapter contains information on

• The operating conditions under which the unit must be used (section 4.2),

• The work necessary for installing the unit (section 4.3),

• The operating area requirements (section 4.4).

4.2 Operating conditions

To guarantee trouble-free operation, the PowerMon and PowerMon S should be used only under the following environmental conditions:

• Free from unidirectional heat radiation or direct sunlight.

• Vibration-free mounting.

• Compliance with the conditions for the specified protection class of the unit. Addi-tional precautions are necessary in areas where corrosive gas or vapour may oc-cur or where there is a risk of explosion.

• Ambient temperature 15 - 35 °C (288 - 308 K); humidity max. 95%, not condens-ing.

• Not for outdoor use! If no building is available, the unit must be installed in a pro-tective cabinet which protects it from the effects mentioned above and which can be air-conditioned if necessary.

• The sample must be homogenous and particle-free. If this is not the case, a filtra-tion system should be connected upstream (e.g. when the unit is used in a waste water treatment plant). You can obtain more detailed information from Bran+Luebbe.

• Unpressurised sample feed. (see also 4.3.3). The pressure of the sample flowing via the bypass must not exceed +/-100 hPa (0.1 bar). If this cannot be guaran-teed, a pressure reducer must be used. This can be ordered from BRAN+LUEBBE (see Fig. 4.4).

• The sample temperature must lie between 15 – 45 °C (288 - 318 K). Otherwise a sample cooling or heating unit must be provided.


• Adequate lighting and sufficient space for maintenance work.

4.3 Installing the unit

The installation of the unit includes the following steps:

• Wall mounting (section 4.3.1)

• Electrical installation (section 4.3.2)

• Hose connections (section 4.3.3)

4.3.1 Wall mounting

The PowerMon and PowerMon S are fixed to the wall.

Fig. 4.1 shows a dimensional installation drawing with the holes for wall mounting.

Warning: The nature of the wall and the screws and dowels or anchor bolts used must be suitable for supporting the weight of the housing, the reagent cabinet if necessary, and the mounting frame. Depending on the configuration, the weight of a PowerMon or PowerMon S in its housing can be up to 125 kg (incl. reagents). We recommend fixing the unit to a concrete wall with M8 screws or anchors.

You will find the necessary information for alternative designs in Appendix B.

Check whether the tilt and shock indicators on the transport box show signs of incor-rect transportation. After drilling the holes, remove the unit from the transport box with a suitable lifting device.

Warning: During transportation and installation, the unit must be secured against falling and tilting. To do this, use suitable lifting devices e.g. a crane with belts.

Sufficient space must be provided in front of the unit for maintenance.

In the case of units with housings, when the unit has been mounted on the wall, open the housing door and remove the hard foam blocks which act as transport safeguards from the analyser plate and the rear of the control section housing (for the latter, undo the knurled nut and pivot the analyser plate upwards). Keep the transport safeguards safely for possible later use (for more information, see the packing instructions in Ap-pendix B). If the unit is supplied with optional reagent cabinets, these are dispatched screwed to the underside of the unit. However, it is also possible to fix the reagent


cabinet to the wall separately. The reagent cabinets for PowerMon and PowerMon S are identical.

1. M16 cable glands for control and signal cables

2. M20 cable gland for mains cable

3. Hose fittings for sample and di-luting water connections DN 4/6

4. Hose fitting for drain DN 10/14

Optional

Fig. 4.1: Dimensional arrangement drawing PowerMon in housing and re-agent cabinet


Fig. 4.2: Dimensional arrangement drawing PowerMon in mounting frame


1. M16 cable glands for control and signal cables

2. M20 cable gland for mains cable

3. Hose fittings for sample and di-luting water connections DN 4/6

4. Hose fitting for drain DN 10/14

Optional

Optional

Fig. 4.3: Dimensional arrangement drawing PowerMon S in housing and two reagent cabinets


4.3.2 Electrical installation

Danger: VDE regulations, the regulations for the prevention of accidents or the ap-propriate local regulations must be observed when carrying out the electrical installation. All cabling and wiring must be carried out by a qualified electri-cian only.

Follow the basic rules below when carrying out the installation:

• Feed all cables into the housing through cable glands.

• Do not run power and signal conductors in the same cable or conduit.

• Lay the signal cables so that they will be free of inductive interference.

• Use only screened cables for signal conductors, and connect all signal conductor screens to the unit earth by means of the earth bar in the electronics housing.

• All connections must make good contact.

Making connections:

You will find the terminal and pin assignment for the electrical connections in the cir-cuit diagrams and terminal diagrams in Appendix B Technical data.

• Mains connection The mains cable with its plug is brought out of the housing.

The PowerMon and PowerMon S are equipped with a universal power supply as standard. You will find the permissible voltage and frequency ranges for the input voltage in Chapter 3.10 Specifications.

The power input is max. 150 VA.

Warning: The unit is switched on when the mains plug is inserted. Measuring may start as soon as initialisation is complete. The unit may not run dry. Therefore, all other electrical connections and the sample and reagent connections should be made before switching on.

• General and limiting value alarms and signal outputs for the measured val-ues Appropriate outputs are provided to transmit unit faults and limiting value trans-gressions, e.g. to a central control room. The outputs are assigned using the op-erating software. You will find the as-delivered assignment in the configuration report in Appendix B.

The loading of the alarm outputs must not exceed the values specified in Chapter 3.10 "Specifications".

In addition, the current measured values for each sample stream can be fed out via analogue signal outputs (current outputs) (e.g. to a control room).


Signal outputs may be loaded with a maximum burden of 500 Ω. The operating software is used to define whether the zero point is 0 or 4 mA.

The expansion board is only installed on multi-stream units with three sample streams and more, and/or if additional analogue inputs and digital inputs and outputs are required. It is mounted on spacing bolts.

Free terminals are plugged onto the contacts.

o To access the control section, loosen the knurled nut on the left-hand side of the analyser plate and swing the plate forward. The control section is mounted on the rear and is opened with a cross-head or flat-bladed screw-driver.

o Then feed the cables into the control section from the bottom through the appropriate grommets.

o Next remove the cable sheath and strip the leads. The screen is connected to the screen bar directly behind the grommet. The screen bar simultaneous-ly acts as a strain relief.

o Connect the cores in accordance with the assignment in the circuit diagram and close the control section.

4.3.3 Hose connections

The following hose connections must be made:

• Sample feed, dilution water (if required) and drain In the case of installations with housing, these connections are brought out via hose fittings at the right-hand bottom side of the housing. The larger opening is intended for the drain. As a general principle, it must be ensured that hoses are always kept as short as possible. You will find details of the hoses in the hose diagram in Appendix B.

Make sure that the hose/connector joints are free from leakages.

When connecting the sample feed, it is essential that the sample is effectively supplied at zero pressure. In the case of higher sample pressures, pressure re-duction valves or overflow vessels must be provided. Please contact Bran+Luebbe if necessary.


Ventilation

¼“ NPT (in side)

Overflow

To PowerMon

Sample

Fig. 4.4: Pressure reducing valves (for 6 measuring points)

In order that the unit is always presented with fresh sample, it is recommended that the sample is fed past the unit via a bypass. In this case, it must also be en-sured that the bypass is free of pressure after the take-off point for the unit. Oth-erwise a vacuum may be produced in the line which leads to the unit.

If necessary, stretch the end of the hose with circlip pliers and wet it with water (PVC hoses may also be heated to about 35 °C, e.g. with a hair drier or hot-air fan).

Warning: It is essential that the sample feed and drain are unpressurised.

As some of the reagents used are aggressive, the waste system must be corro-sion resistant.


The local regulations concerning disposal of chemical waste into the public sew-age system must be observed.

Danger: It is possible for hose couplings to come loose due to blockages in the hose system. Under certain circumstances, this may cause dangerous liquids to spurt out. In the case of units with housings, the housing will protect the operator against splashes. Before opening the housing, check for leaks by looking through the window in the housing door. In the case of units without housings, work may only be carried out in the vicinity of the unit when wearing eye protection and suitable protective clothing. The measures depend on the application. Pay attention to the reagents that are used and to the composition of the sample.

• Connection of the peristaltic pumps The metering hoses in the peristaltic pumps are removed from the holder before shipping in order to relieve the strain. The following steps are required to refit them:

o Loosen the retaining plate and remove the hose-bed (see Fig. 4.5) o Fit the metering hose around the rotor without twisting. o In the case of 4-channel peristaltic pumps, press the loosened side of the

hose bed against the holder until it engages. The metering hoses must first be secured without twisting in the hose bed guides by means of the slides if necessary.

Warning: Make sure that the liquid (sample, reagent or diluting water) is transported into the unit in accordance with the direction of rotation of the pump. (See hose plan in the method description in Appendix B).

o Switch on the unit by plugging in the mains lead. The unit will initialise itself and will then be in the STOP mode. However, if the measurement should start automatically, stop it by pressing Menu - Service - Status - Stop. A shut-down sequence of 60 seconds is normally carried out first, during which several pumps and valves are active.

o The appropriate pumps can be started manually for approximately 30 sec-onds by pressing keys P1 to P6 under Menu – Service – Status – Manual. This prevents twisting, which reduces the life of the metering hoses. The pumps are stopped by pressing the keys once more. Speed and direction are preset.

Warning: There is a risk of crushing when the hose bed is removed and the rotor is turning.


o Refit the hose bed, press the fixing bolts against the fixing bracket from be-hind and refit the retaining plates.

o Unplug the mains lead.

1 Motor 2 Gearbox 3 Fixing bracket 4 Hose bed 5 Rotor 6 Protective cover 7 Retaining plate

8

2 7

5 6

1 4

8 Spring mounted fixing pins

3

Fig. 4.5: Arrangement drawing of single-channel peristaltic pump

Fig. 4.6: Arrangement drawing of 2-channel peristaltic pump


1 Motor 2 Gearbox 3 Fixing bracket 4 Hose beds 5 Rotor

62

45

1 6 Bracket for hose

beds

3

Fig. 4.7: Arrangement drawing of 4-channel peristaltic pump

4.4 Workplace design

Because chemicals are used in the operating area, the following requirements must be fulfilled when designing the workplace:

• Good ventilation The exhaust air must be directed away from the area where people work to pre-vent them from inhaling harmful substances. Some Bran+Luebbe monitors have a ventilation system to which hazardous substances in gaseous form (e.g. re-agent vapours) are connected. This ventilation system must be ducted out of the monitor area by means of a hose when the system is installed.

• Danger labelling

o Working areas must be labelled by means of: o Warning signs which indicate dangers o Mandatory signs for required personal protective equipment o Prohibition signs (e.g. no smoking or no access) o Information signs (e.g. first aid or behaviour in the event of a fault)

• Safety equipment for first aid Working areas must be equipped with eyewashes (2 bottles are recommended; pay attention to the shelf life) and personal protective equipment. This includes suitable eye protection (safety glasses or safety screen), suitable hand protec-tion, a cotton apron and safety shoes. Suitable protective equipment can be seen


from the operating instructions specific to the unit and to the material (see Sec-tion 2.5).

Bran+Luebbe PowerMon Chapter 5 Commissioning and decommissioning 47

55 CCOOMMMMIISSSSIIOONNIINNGG AANNDD DDEECCOOMMMMIISSSSIIOONNIINNGG

5.1 Overview

After installation the unit can be started up. This consists of the following steps:

• Preparing the unit, e.g. connecting the necessary reagents (section 5.2).

• Starting the measuring process (section 5.3).

• Decommissioning is described in Section 5.4.

5.2 Preparing the unit

The following description assumes that the unit has been fully and correctly installed as described in the previous chapter, i.e. that all hoses have been connected and all connections made.

1. Place the reagents in the transport canister below the unit or into the optional re-agent cabinet. In the first case, make sure that the difference in height between the canisters and the associated pumps is not more than 1000 mm.

2. If diluting water is required for your application (see method description in Ap-pendix B), provide deionised or drinking water at the appropriate connection de-pending on the requirement.

3. Place the immersion tubes into the appropriate reagent containers and screw down the caps.

Caution: When doing so, make sure that the reagent number on the hoses corre-sponds to that on the containers.

4. In the case of Ionometers, carefully remove the cap from the measuring cell and fill the outer vessel with tap water until it overflows (do not use deionised water as the conductivity will otherwise be too low). Put the cover back onto the cell. Re-move the measuring electrode and if available the reference electrode from the packaging and prepare them for use as described in the attached information. In-sert the electrode(s) in the cap of the measuring cell in accordance with the in-structions provided.


Warning: It is essential that the measuring cell be filled with water before use if it is fitted with a heating element. Otherwise the heating element may burn out.

5.3 Starting the measuring cycle

After completing the preparations in section 5.2, the measurement can be started:

1. Switch on the unit by plugging in the mains lead. The unit will initialise itself and will then be in the STOP mode. However, if the measurement should start auto-matically, stop it by pressing Menu - Service - Status - Stop. A shut-down se-quence of 60 seconds is normally carried out first, during which several pumps and valves are active.

2. Start the sample feed by switching the filtration on (if connected). Adjust the sample flow depending on the application to approx. 1.0 – 3.0 l/h.

3. Start the appropriate pumps by pressing keys P1 to P6 under Menu – Service – Status – Manual until all metering paths are filled with reagent, calibration solu-tion or sample. Valves may also have to be activated for this purpose. To do this, display all available valves with the ⇓ key under Manual in the menu. V1 to V6 are assigned to the sample valves. If the unit has a drain valve, this can be acti-vated by pressing V8. You can see the exact assignment of all the configured outputs in the equipment diagram in the method description in Appendix B.

4. Observe the filling process. Exit Manual when all the hoses are full. 5. If liquid is not pumped due to a dry hose, switch off the appropriate pump. Then

loosen the retaining plate on the peristaltic pump, remove the hose bed, undo the pressure end of the hose and suck liquid as far as the pump with a syringe. Then retighten the hose bed and the retaining plate and re-connect the hose.

6. In the case of Ionometers that are fitted with a heating circuit, this will have been deactivated before shipping and must be activated before starting the measure-ment. This is done by pressing the OFF key under Menu - Application - Heating circuit. ON is then displayed on the key. If you now leave this menu item, the heating circuit is activated. (Application on the menu is password protected. You will find the password (PIN) in the attached configuration data sheet).

7. The unit is switched to the MEASURING mode via Menu - Service - Status - Measuring. The analysis programme will start automatically.

Bran+Luebbe PowerMon Chapter 5 Commissioning and decommissioning 49

Danger: It is possible for hose couplings to come loose due to blockages in the hose system. Under certain circumstances, this may cause dangerous liquids to spurt out. In the case of units with housings, the housing will protect the operator against splashes. Before opening the housing, check for leaks by looking through the window in the housing door. In the case of units without housings, work may only be carried out in the vi-cinity of the unit when wearing eye protection and suitable protective clothing.Please refer to the safety information on the mounting plate. The measures depend on the application. Refer to the information for the reagents used and to the composition of the sample.

Automatic analysis sequence

No further user action is normally necessary as the programme sequence and the operating parameters for your unit have all been entered by Bran+Luebbe.

Measurements will be displayed on the touch screen when the first analysis cycle is complete. On single-stream monitors, these are overwritten by each subsequent analysis measurement so that the latest value is always stored in the system memory and shown on the display. On multi-stream systems, you can choose between rolling and continuous display mode. The display mode can be set via the touch screen.

Some systems running at very low levels often show relatively high drift on start-up. This is due to dirt in the hose system which, however, will be washed out in time. The values are normally stable after a few hours. It is advisable to initiate some calibra-tions manually to check the stability of calibration factors. The procedure will be found in the operating manual for the operating software.

In the case of units with heating elements, the error message "Low temperature" may appear after switching on. The error message will disappear when the desired tem-perature is reached. The unit should only be calibrated at this point, as prior to this the measurement may be unreliable.

If required, you can display and alter the operating parameters, e.g. the calibration frequency or the limit values. The procedure will be found in the operating manual for the operating software. The special settings for your unit are shown in the method de-scription or in the configuration report in Appendix B.

Warning: Do not go outside the limits specified in the method description or configura-tion report in Appendix B, as this may affect the measuring operation.

Follow the maintenance instructions in Chapter 7.


5.4 Decommissioning

The following steps are required before an extended shutdown:

1. Stop the measurement via Menu – Service – Status – Stop. 2. Stop the sample feed (if a filtration system is connected, stop the filtrate pump).

3. Unscrew the extraction lines from the reagent canisters.

4. Immerse all hoses in a container with fully desalinated water and start the appro-priate pumps by pressing keys P1 to P6 under Menu – Service – Status – Manual and open the drain valve if fitted by pressing V8. Pump water through the hoses for about half an hour.

5. Remove hoses from the water to that air is now pumped through them. Allow the pumps to run until the entire hose system is completely empty.

6. Exit Manual to switch off the pumps. 7. Loosen the peristaltic pump retaining plate, remove the hose beds and remove

the metering hoses from the rotor to relieve the strain on them. In the case of 4-channel pumps, press against the engaged side of the hose beds to release. The hoses can be fixed to the pumps with rubber bands.

8. With Ionometers and Titrometers, remove the electrodes from the measuring cell and store them as described in the electrode descriptions supplied.

Warning: Electrodes can be irreversibly damaged if they are not stored correctly.

9. With Ionometers, the heating circuit must also be deactivated. This is done by pressing the ON key under Menu - Application – Heating circuit. OFF is then displayed on the key. If you now leave this menu item, the heating circuit is deac-tivated. (Application on the menu is password protected. You will find the pass-word (PIN) in the attached configuration data sheet). The vessel of the measuring cell can now also be emptied. To do this, pivot the analyser section upwards, un-fasten the measuring cell drain hose, remove the measuring cell cap, loosen the knurled nuts on the retaining plate, empty the measuring cell vessel into a dis-posal container and rinse with clean water.

Danger: The liquid in the measuring cell vessel may contain corrosive and hazardous substances. Work must be carried out with appropriate care and protective clothing must be worn.

Make sure that the magnetic stirring rod is not lost when emptying the meas-uring cell vessel.

10. Unplug the mains lead to switch off the unit. If the device is to be transported, re-fit the transport safeguards before dismantling (see packing information in Ap-pendix B).

Bran+Luebbe PowerMon Chapter 6 Using the operating software 51

66 UUSSIINNGG TTHHEE OOPPEERRAATTIINNGG SSOOFFTTWWAARREE

The use of the operating software is explained in the separate operating manual.

The operating manual must be kept together with this user manual near to the unit.

Bran+Luebbe PowerMon Chapter 7 Care and maintenance 53

77 CCAARREE AANNDD MMAAIINNTTEENNAANNCCEE

7.1 Overview

Certain maintenance work must be carried out at regular intervals to ensure that the unit operates reliably and with as few problems as possible.

The work carried out should be recorded in a maintenance report. On the one hand, this is useful for maintaining an overview, and on the other for simplifying the work for our service engineer if required. You will therefore find a master maintenance report form for photocopying on the last page of this chapter.

The following gives a list of which maintenance work should be carried out at what in-tervals. You will find more detailed information on the individual maintenance tasks in the following sections.

The maintenance intervals specified below are only indicative. It may be nec-essary to carry out certain work earlier depending upon the environmental conditions.

• Daily (see Section 7.2): o Visual inspection of the analyser

• Weekly (see Section 7.3): o Visually inspect reagent supply and top up if necessary o Check operation of flow monitors and readjust if necessary

• Quarterly (see section 7.4): o Check valves for leaks o Replace metering hoses and check peristaltic pumps o Check multi-channel pump hose beds and replace if necessary o Check pump rotors o Check hose system o Clean flow cell and/or measuring cell o Check the calibration factors for plausibility o Check electrodes and top up internal electrolyte if necessary

• Yearly (see section 7.5) The following work should be carried out by a service engineer as part of a ser-vice contract with Bran+Luebbe:


o Replace all hoses o Check peristaltic pump rotors and replace if necessary o Check operation of valves and replace if necessary o Check measuring and reference electrode and replace if necessary o Replace all seals and O-rings

7.2 Daily maintenance

• Visual inspection of analyser A daily check should be carried out for leaks in the analyser or other abnormali-ties.

7.3 Weekly maintenance

• Checking the reagent supply A check should be carried out to ensure that there is still an adequate supply of reagent in the reagent containers. Keep new reagents ready for use if needed.

• Checking the operation of the flow monitors The LED must illuminate orange when the hose in the flow monitor is filled with liquid. If there is air in the hose, the LED illuminates red. If there is a discrepancy, the sensitivity of the monitor can be adjusted using the potentiometer screw. Turning clockwise reduces the sensitivity of the monitor and vice versa.

7.4 Quarterly maintenance

• Checking valves for leaks

o Press STOP and activate and deactivate the appropriate valves under Menu – Service – Status - Manual. A click must be heard when activating the val-ve.

o Sample valves: Clamp off the calibration solution hose with forceps to pre-vent the calibration solution from running back. Carefully loosen the middle hose of the sample valves with a screwdriver.


If the sample valve is working properly, no liquid may escape from the nipple. If liquid escapes, you should first check whether reducing the sample flow (or fil-trate flow if a filtration system is connected) solves the problem, otherwise the valve must be cleaned or replaced.

o Replace the ends of the hose on the nipples above the valves, remove the clamp from the calibration solution hose and

o start normal measurement.

• Replacing the metering hoses in the peristaltic pumps

o Press STOP. o Stop the liquid feed by clamping off the hose to the reagent container or

sample feed with forceps.

o Loosen the suction-side hose connection on the peristaltic pump. Start the appropriate pumps by pressing keys P1 to P6 under Menu – Service – Sta-tus – Manual and open the drain valve by pressing V8 (not Ionometer). Wait until all hoses within the analyser are free so that no reagents can run back and escape. Exit Manual and loosen pressure-side hose connection.

o Remove the retaining plate and the hose bed. o Clean the hose bed and lubricate rotor and springs in the hose bed with a

drop of oil (see also Fig. 4.5). If cracks or holes are visible on the surface of the rollers or if the rollers are worn and have too much play, the rotor must be replaced.

o Remove old metering hose. o Fit the new metering hose around the rotor without twisting. o Refit the hose bed and the retaining plates. o In the case of multi-channel pumps, press against the engaged side of the

hose beds to release and disengage the hose beds with the metering hoses.

o Remove old metering hoses. o Secure new metering hoses in the hose beds without twisting by means of

the slides.

o Refit and engage hose beds.

Warning: There is a risk of crushing when the hose bed is removed and the rotor is turning.

o Reconnect hoses in accordance with the hose diagram in Appendix B. o Remove forceps. o Start the appropriate pumps by pressing keys P1 to P6 under Menu – Ser-

vice – Status – Manual to fill the hoses. o Exit Menu – Service – Status – Manual when all hoses are filled. o If liquid is not pumped due to a dry metering hose, switch off the appropriate

pump. Then loosen the retaining plate on the peristaltic pump, remove the


hose bed, undo the pressure end of the hose and suck liquid as far as the pump with a syringe. Next retighten the hose bed and the retaining plate and re-connect the hose.

o Return the unit to the MEASURING mode.

New metering hoses must first be run-in for a few hours in order to rinse the dirt out of them before the measurements remain stable. It is recommended that a calibration be started manually after a little time.

• Checking the peristaltic pumps Check that the pumps are pumping liquid by sucking in an air bubble and watch-ing its progress along the tube. In the case of the reagent pumps, all you need to do is to briefly lift the dip tube out of the liquid while the pumps are running. With the sample feed pump, you must interrupt the hose connection at one point, keep the end of the hose closed and then open the upper end briefly to suck in an air bubble. Then seal the hose again.

If the air bubble does not move, the pump hose may be defective, the hose bed may not be properly fixed, or the rolls of the rotor may be defective.

• Checking the hose beds of the multi-channel pumps If the quantities pumped by the multi-channel pumps should not be sufficient, first check the metering hoses for blockages. It may be that the spring contact pres-sure in the hose bed is no longer adequate. In this case, the hose bed must be replaced.

• Checking the pump rotors If cracks or holes are visible on the surface of the four rollers or if the rollers are worn and have too much play, the rotor must be replaced.

• Checking the hose system Check all hoses for proper seating, contamination, algae growth, blockages and leaks.

If the hoses are very dirty, you should clean them with diluted sodium hypochlo-rite solution:

o Press STOP. o Ionometer/Titrometer: Remove the electrodes from the cap of the measur-

ing cell. Pull out the measuring electrode slowly with a slight clockwise rota-tion.

Warning: The electrodes must not come into contact with the sodium hy-pochlorite solution, as otherwise they may be destroyed.

o Carefully slide off the sample feed hose from the peristaltic pump with a screwdriver.


o Inject approx. 50 ml diluted sodium hypochlorite solution slowly with a sy-ringe (commercially available sodium hypochlorite (13% active chlorine) di-luted 1:10 with tap water). Repeat in the case of severe contamination.

Danger: Avoid sodium hypochlorite contact with skin, mucous membranes or eyes! Wear safety glasses and protective gloves.

o Tygon hoses that have become milky in appearance will not interfere with correct operation.

o Using a syringe, now rinse at least three times with fully desalinated water to remove all traces of sodium hypochlorite solution.

o Ionometer/Titrometer: Refit the electrodes. o Reconnect the hose to the sample pump and select MEASURING mode.

If a filtration system (with rinsing unit) is fitted, you can also pump diluted sodium hypochlorite solution through the monitor from the filtration system if the filter hoses are cleaned there.

o If this does not help or if hoses are leaking, you should replace the hoses. To do this, first stretch the new hoses with circlip pliers, moisten, and then push onto the connector.

• Cleaning the flow cell and/or measuring cell The flow cell or measuring cell can be cleaned in the same way as the hose sys-tem. Depending on the type of contamination, it may be necessary to use other cleaning agents. The type of cleaning agent required must be matched individu-ally to the type of contamination.

In order to prevent breakage of the glass nipple of the flow cell, you should always cut open the hose sleeve with a sharp knife when removing the flow cell. Try not to pull off the hose sleeves or lever them off with a screwdriver.

Glass parts are excluded from the warranty.

• Checking the calibration factors for plausibility On the one hand, keeping a record helps in assessing the functional capability of the unit and, on the other, makes it easier for the service engineer to find faults more quickly. To read out the values, press Menu – Service – History.

• Topping up the electrolyte (for Ag/AgCl reference electrode only) If an Ag/AgCl reference electrode is used for the measuring process, top up the bridge electrolyte as far as the refill nozzle (see method description in Appendix B for the reagent number). The bridge electrolyte should always be some centi-metres above the surface of the measuring solution in the measuring cell to en-sure that there is sufficient primary pressure and that the electrolyte can flow slowly into the measuring solution.


• Checking the electrodes The electrodes have a limited working life which depends on the type of electrode and the measuring medium. As a preventative measure, they should be checked every month and replaced after no more than on

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