PHOTOVOLT. AQUATEST VA 2010 Moisture Vaporizer for AQUATEST 2010 KF Coulometric Titrator. Photovolt Instruments. Installation and Instruction Manual

Transcription

1 PHOTOVOLT AQUATEST VA 2010 Moisture Vaporizer for AQUATEST 2010 KF Coulometric Titrator Installation and Instruction Manual Photovolt Instruments

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3 WARNING This manual contains information and warnings which must be followed to ensure proper and safe operation of your AQUATEST 2010/VA For accurate results and safe use of the AQUATEST 2010/VA 2010, correct operation and maintenance including periodic inspection are required. You should read the instruction manual paying attention to all warnings and notes prior to practical use and maintenance of your instrument. Cautions regarding operation of the AQUATEST 2010/ VA 2010 are indicated by the following format throughout the instruction manual. Be sure to read and understand all of these cautions. WARNING NOTE POINT Indicates actions or conditions that pose a hazard(s) to the user. Indicates actions or conditions that may damage your AQUATEST 2010/ VA 2010 or result in inaccurate test results. Indicates information important for the accurate use of the AQUATEST 2010/ VA 2010 system. The AQUATEST 2010 Moisture Analyzer has been designed and tested according to IEC Publication This manual contains information and warnings that must be followed to ensure proper operation and maintain the instrument in safe condition. Some common International electrical symbols used on the instrument and in this manual are shown below. o I Power Switch OFF position Power Switch ON position Earth Ground See Explanation in Manual Hot Surface This document contains information for use by owners and operators of the Photovolt Instruments AQUATEST Information in this document is subject to change without notice. This document is considered proprietary and no part may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express prior written consent of Photovolt Instruments. If copies are then permitted, they must contain this proprietary notice Photovolt Instruments. All rights reserved. i

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5 AQUATEST VA 2010 Moisture Vaporizer for the AQUATEST 2010 KF Coulometric Titrator Installation and Instruction Manual (Revision C) Photovolt Instruments 6323 Cambridge Street Minneapolis, Minnesota Telephone: ; Fax: Internet:

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7 TABLE OF CONTENTS TABLE OF CONTENTS... V LIST OF FIGURES... VII LIST OF TABLES... VII SECTION 1: INTRODUCTION... 1 PRINCIPLE OF MOISTURE DETERMINATION USING THE AQUATEST VA 2010 MOISTURE VAPORIZER... 1 SECTION 2: SAFEGUARDS AND PRECAUTIONS... 3 GENERAL INFORMATION... 3 DECLARATIONS... 3 SAFEGUARDS AND PRECAUTIONS FOR INSTALLATION... 3 PROPER USE... 5 PRECAUTIONS FOR HANDLING COMPRESSED GASES... 5 CHANGING THE FUSES OF THE VAPORIZER... 6 MODIFYING THE OPERATING LINE VOLTAGE... 7 SERVICE... 9 SECTION 3: SYSTEM DESCRIPTION INSPECTION OF PARTS VA 2010 MAIN UNIT VA 2010 OVEN UNIT VAPORIZER STANDARD ACCESSORIES Gas Dispersion Tube Sample Boats way Vent Tube Main Oven Tube Vaporizer Interface Cable Vaporizer Power Input Cord Pushrod Assembly Desiccant Cartridge Assembly Boat Extraction Tool Platinum RTD Vaporizer Interface PC Board Fittings Kit Gas Line Tubing SECTION 4: INSTALLATION AND SETUP UNPACK THE VA 2010 THERMAL MOISTURE VAPORIZER INSTALL THE VAPORIZER INTERFACE PC BOARD SET UP THE CONTROL UNIT Page v

8 INSTALL THE DESICCANT CARTRIDGE...20 CONNECT THE GAS SUPPLY LINES...21 Using Quick-Connect Tubing Fittings...21 Using Threaded Teflon Tubing Fittings...22 Nitrogen In...22 Valve and Desiccant Connection...22 Purge Line Connection...23 ATTACH THE OVEN MODULE...23 INSTALL THE MAIN OVEN TUBE...23 ATTACH THE PLATINUM RTD...24 ATTACH THE HEATED TRANSFER LINE...24 INSTALL THE 3-WAY VENT TUBE...25 INSERT THE LOADER PUSHROD AND SAMPLE BOATS...25 CONNECT THE GAS DISPERSION TUBE...26 OPERATING THE AQUATEST VA SECTION 5: PREPARING FOR OPERATION...27 VAPORIZER DISPLAY...27 LOADER TEST...27 SETTING GAS FLOW...28 SETTING THE OVEN TEMPERATURE...30 SECTION 6: OPERATION OF THE VAPORIZER ACCESSORY...31 BLANK REDUCTION PROCEDURE...31 SHUTTING DOWN THE VAPORIZER...32 SECTION 7: MAINTENANCE...33 GENERAL MAINTENANCE...33 GAS LINE DESICCANT WAY VENT DRYER TUBE...34 OVEN DOOR SEAL...34 MAIN OVEN TUBE...34 SAMPLE BOATS...34 HEATED TRANSFER LINE...35 ELECTRO-CONDUCTIVE OVEN GLASS...35 SECTION 8: SUPPLIES AND REPLACEMENT PARTS...37 VAPORIZER CONSUMABLE PARTS...37 OPTIONAL ACCESSORIES...37 Large Sample Chamber (P/N: )...37 SECTION 9: WARRANTY INFORMATION...39 NEW INSTRUMENT WARRANTY...39 OPERATOR S MANUAL WARRANTY...40 Page vi

9 LIST OF FIGURES Page Figure 1 - Location of the Voltage Select Switch...8 Figure 2 - Location of the Fuse Drawer...8 Figure 5 - AQUATEST VA 2010 Rear View...12 Figure 7 - AQUATEST VA 2010 Top View...12 Figure 9 - Oven Unit Showing Electrical Connection...13 Figure 11 - Gas Dispersion Tube...14 Figure 7 - Sample Boats...14 Figure 8-3-way Vent Tube...14 Figure 9 - Main Oven Tube...15 Figure 10 - Vaporizer Interface Cable...15 Figure 11 - Pushrod Assembly (shown with Sample Boat)...16 Figure 12 - Desiccant Cartridge Assembly...16 Figure 13 - Boat Extraction Tool...17 Figure 14 - Platinum RTD...17 Figure 21 - Vaporizer Interface PC Board...17 Figure 16 - AQUATEST 2010 with Vaporizer I/F PCB installed Figure 18 - Desiccant Cartridge...21 Figure 20 - Platinum RTD and Heated Transfer Line Installation...24 Figure 22 - Use of the 3-Way Vent Tube...25 Figure 24 - Sample Boat Oven Position...28 Figure 26 - Sample Boat Home Position...28 Figure 22 - AQUATEST VA 2010 Gas Flow Rate Indicator...29 Figure 24-3-Way Vacuum Relief Valve Vent Position...29 Figure 30-3-Way Vacuum Relief Valve Operating Position...29 Figure 26 - Large Sample Chamber...38 LIST OF TABLES Page Table 1 Fuse Specifications...7 Table 3 Standard Accessories...11 Table 4 - Vaporizer Status Indicators...27 Table 5 Vaporizer Consumable Parts...37 vii

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11 Section 1 AQUATEST VA 2010 SECTION 1: INTRODUCTION PRINCIPLE OF MOISTURE DETERMINATION USING THE AQUATEST VA 2010 MOISTURE VAPORIZER The AQUATEST VA 2010 Vaporizer accessory allows moisture to be determined in many samples that are not compatible with the method of direct addition to the reagents in the vessel. If a component of the sample interferes with the Karl Fischer reaction, or if the moisture is present in very low concentrations in a solid material, the VA 2010 can be a valuable addition to the AQUATEST 2010 system. In the AQUATEST VA 2010, a flowing stream of dry gas, usually nitrogen, is fed through a tubular analysis chamber. A portion of the chamber is heated at temperatures up to 300 C. The sample is loaded into a pre-dried glass boat in a cool portion of the tube. The gas stream is allowed to flow by the sample to remove ambient moisture. The gas stream is then diverted through the heated portion of the tube and eventually into the AQUATEST 2010 titration vessel. When the sample boat is moved into the heated area of the tube, the moisture from the sample is driven off and carried into the titration vessel by the gas stream. The AQUATEST 2010 senses the presence of moisture and proceeds to titrate as if the sample had been injected into the vessel. After the gas stream has carried all of the moisture from the sample into the vessel and the titration is complete, the AQUATEST 2010 calculates the total amount of moisture evolved from the sample. The temperature of analysis is experimentally determined for a sample matrix. This is normally selected to be the highest temperature at which the water can be driven off the sample where combustion of the sample matrix does not occur. The endpoint detection algorithm in the AQUATEST 2010 Titrator controls the time of the analysis. The instrument will continue to titrate until it no longer detects moisture generated from the sample. Page 1

12 AQUATEST VA 2010 Section 1 AQUATEST VA 2010 SPECIFICATIONS Temperature Range 50 C to 300 C (at an ambient temperature of 25 C) Oven Type Transparent Electro-Conductive Glass, 120 VA Temperature Control Through AQUATEST 2010, 3 Digits Sample Capacity Up to 10 grams (depends upon sample matrix) Gas Requirements 100 to 500 ml/min Oxygen-Free Nitrogen (99.999% Nitrogen) Inlet Pressure 2 kg/cm 2 g (30 psig) Flow Control Regulated by Fine Needle Valve Flow Display 5-step Display of Flow on LCD Gas Supply Dryer Non-Toxic Replaceable In-line Drying Agent Sample Introduction Automatic Sample Boat Loader Moisture Transfer Via Heated Gas Transfer Line (105 C) Blank Reduction Automatic Moisture Purge System Ambient Temperature Range 5 C to 40 C Ambient Humidity Range 85% or Less (Condensation Should Be Avoided) Dimensions Approx. 508 mm (W) x 203 mm (D) x 178 mm (H) 20 (W) x 8" (D) x 7" (H) Weight (Packed) 6.1kg (13.25 lbs) Note: The AQUATEST 2010 Karl Fischer Coulometric Titrator is required to operate this unit. The AQUATEST VA 2010 cannot be used without the AQUATEST 2010 Titrator. Page 2

13 Section 2 AQUATEST VA 2010 SECTION 2: SAFEGUARDS AND PRECAUTIONS GENERAL INFORMATION Careful attention has been given to this product to assure a quality standard dedicated to your safety and to the proper operation of this unit. This quality standard, together with your personal responsibility for the safety of yourself and others, will contribute to the safe and proper operation of this product. This instrument uses electrical energy and requires proper handling at all times. READ AND RETAIN THIS INSTALLATION AND INSTRUCTION MANUAL. To make full use of the safeguards incorporated in this unit, read and follow this basic guide before operating this product. For easy maintenance, confident operation, and troublefree service, FOLLOW THE INSTRUCTIONS AND HEED ALL WARNINGS on the unit and in this manual. DECLARATIONS The AQUATEST 2010 Karl Fischer Coulometric Moisture Titrator complies with the following regulations: Electromagnetic Emissions: Electromagnetic Immunity: Low Voltage Directive: EN EN55022 Class B EN IEC kV Air IEC V/m MHz IEC kv Common Mode, 0.5 kv Capacitive Clamp EN SAFEGUARDS AND PRECAUTIONS FOR INSTALLATION WARNING Follow all precautions listed in the sections titled "Safeguards and Precautions for Installation" and Proper Use. All items in these sections are important for the safety of the user and proper operation of the AQUATEST Operate from a power source indicated on this product or in this manual. Your electric utility service company or a qualified electrical contractor can verify the power source in Page 3

14 AQUATEST VA 2010 Section 2 your facility. It is recommended that all equipment be plugged into a surge-protected electric outlet. Power for the AQUATEST VA 2010 Vaporizer accessory must be supplied through the AQUATEST 2010 Titrator. Do not substitute any other power source. Power supply cords should be protected (particularly at plug-ins, convenience receptacles or cord exit points from the unit) and routed so that they are not rested on, rolled over, walked on, or otherwise subjected to abuse. This is an IEC Safety Class 1 (grounded enclosure) product. For safety, the ground wire in the line cord must be connected to a true Earth Ground when operating from AC power. Frayed or damaged cords and plugs should be replaced by a qualified service technician. Overloaded wall outlets and extension cords present dangerous risks of fire or electrical shock. Avoid blocking ventilation holes. Your AQUATEST 2010 cabinet has ventilation openings to release heat generated during operation. Blocking these openings can cause internal heat build-up that may result in a fire hazard, equipment failure or permanent heat damage to the internal electronic components. Avoid extremely hot locations or sudden changes in temperature, such as placing the unit near a heat source or transporting it between areas of extreme temperature variation. If the unit is suddenly moved from a cold place to a warm place, moisture may form inside of the unit. To avoid injury to the operator or damage to the instrument, use the unit in an upright position and do not place anything heavy on the unit. Do not place unsecured equipment on a sloping surface. Support for the unit should be adequately firm, level, and strong. Replace any unstable cart, table, or support. Carefully follow all operating instructions and use the manufacturer s recommended accessories when operating this unit or connecting it to any other equipment. Install the AQUATEST 2010 in a location that will provide adequate ventilation. Long term exposure to Karl Fischer reagents and the components of many samples can have adverse health effects. Some samples may produce noxious vapors when heated. Use an approved fume hood if necessary. Page 4

15 Section 2 AQUATEST VA 2010 PROPER USE Do not use this product for any purpose other than that for which it was intended. When storing or moving the instrument refer to the section of this manual titled Safeguards and Precautions. Do not use this product in a location where it will be exposed to water. Use only those accessories recommended by the manufacturer in order to avoid risk of fire, shock, or other hazards. Unplug all equipment exposed to rain, moisture, or strong impact. If your instrument has been exposed to rain, water, or excessive moisture or subjected to strong impact, unplug it immediately. Have the instrument inspected by a qualified service technician before use. Unplug all equipment during a storm or when not in use for extended periods of time. During a lightning storm or before leaving the unit unused for extended periods of time, disconnect all equipment from the line power source. Unplug all equipment before cleaning. Then use a clean, dry, chemically untreated cotton cloth to wipe the unit. Use no cleaning fluids, aerosols or forced air that could overspray or soak into the unit and cause electrical shock. Substances such as wax and adhesive tape may affect the cabinet surface. Exposure to greasy, humid or dusty areas may affect internal components. Avoid the following: Spilling liquids into the instrument, inserting fingers or foreign objects into the instrument and positioning the instrument near sources of strong magnetic or electrical interference. Do not operate if an excessive quantity of liquid is spilled in or on the unit; unplug the unit immediately and have it inspected by a qualified service technician. Fire and shock hazards can result from electrical shorts caused by liquid contact inside the case. Be careful not to drop or push objects into the unit. Some parts inside carry hazardous voltages and contact can cause electric shock. Objects dropped in electrical equipment can cause fire hazards. Do not place the instrument near any interference-causing appliances. Keep all magnets away from electronic equipment. PRECAUTIONS FOR HANDLING COMPRESSED GASES In most cases, the AQUATEST VA 2010 will usually be supplied with dry nitrogen gas from a compressed gas cylinder. Be sure to follow all safety precautions suggested by the manufacturer of the cylinder and related equipment. Some of the precautions are listed below. Compressed gas cylinders must be firmly anchored before removing the nozzle cover. Protect the cylinder from extremes of heat and cold. Page 5

16 AQUATEST VA 2010 Section 2 Do not expose the cylinder to an open flame. Use an appropriate compressed gas regulator to reduce the gas pressure going to the instrument. When running long lengths of gas tubing, use only approved compressed gas fittings. Always check the gas pressure BEFORE connecting the gas line to the AQUATEST VA Always operate within the specified gas pressure limits. WARNING Do not use combustible gases with the AQUATEST VA Do not use oxygen or gas mixtures containing oxygen with the AQUATEST VA Doing so may create an explosion hazard with risk of personal injury and/or equipment damage. CHANGING THE FUSES OF THE VAPORIZER The AQUATEST VA 2010 has two 5mm x 20mm fuses located in the Oven Module assembly. NOTE The AQUATEST VA 2010 is shipped without the Oven Module fuses installed. Prior to applying power, verify that the fuses are installed in the fuse drawer in the Oven Module. To replace the fuses: 1. Unplug the Power Input Cord that is attached between the Vaporizer Interface PC Board and the Oven Module assembly. 2. Locate the fuse drawer on the back of the Oven Module. 3. Press down on the release tab on the fuse drawer to release the drawer. 4. Remove the installed fuses and replace with two fuses having the same specifications. 5. Replace the fuse drawer in the Oven Module and securely lock it in place. 6. Reattach the Power Input Cord. WARNING For protection against fire, replace both fuses only with two of identical rating. Refer to the Table 1 for proper fuse ratings for selected voltage. Page 6

17 Section 2 AQUATEST VA 2010 Unit Voltage Rating Fuse Description Oven Module 100/115 5mm x 20mm, 2A, 250V, Slow Blow UL Listed 220/240 5mm x 20mm, 2A, 250V, Slow Blow UL Listed Titrator 100/115 Type T, 0.4A, 250V, Slow Blow UL Listed 220/240 Type T, 0.2A, 250V, Slow Blow IEC Approved Table 1 Fuse Specifications MODIFYING THE OPERATING LINE VOLTAGE NOTE The AQUATEST VA 2010 is designed to operate at nominal line voltages of 100/115/220/240 VAC. To prevent damage to the Vaporizer unit, the operating voltage for the Vaporizer must be set to the same input voltage selected on the rear panel of the AQUATEST 2010 Titrator base unit. WARNING Use only a properly grounded power source. When changing the input voltage, the fuses may also have to be changed for proper protection from fire. Refer to Table 1 for the proper fuse rating. 1. The selected operating voltage for the Titrator is indicated by the red notch on the Voltage Selection switch on the Titrator base unit. To change the operating voltage, first unplug the Power Supply Cord from the rear panel of the Titrator base unit and remove the Power Input Cord connecting the Oven Module assembly to the Vaporizer Interface PC Board. 2. Open the fuseholder on the Titrator base unit and remove both fuses. Replace both fuses with the fuses specified in Table 1 for the selected input voltage. (Whether the voltage is being changed from 110/115V to 220/240V or from 220/240V to 110/115V, both fuses in the Titrator base unit must be changed.) 3. Replace the fuseholder, and using a flat blade screwdriver, turn the rotary dial so that the newly selected voltage is indicated on the Voltage Selection switch. 4. Remove the Vaporizer Interface PC Board from the Titrator base unit. 5. Check the position of the Voltage Select toggle switch on the Vaporizer Interface PC Board. If the Titrator has been set to operate at 100V or 115V, move the Voltage Select toggle switch on the Vaporizer Interface PC Board to the position labeled 100V. If the Titrator has been set to operate at 220V or 240V, then move the Voltage Select toggle switch to the position labeled 200V. 6. Replace the Vaporizer Interface PC Board. 7. Reconnect the Power Input Cord and the Power Supply Cord. Refer to Figure 1 for the location of the Voltage Select toggle switch. Refer to Figure 2 for the location of the fuse drawer. Page 7

18 AQUATEST VA 2010 Section 2 Card Edge Connectors P6 P7 P5 SW1 BLK GRN WHT 100VA 200VA Voltage Select Toggle Switch - G + Figure 1 - Location of the Voltage Select Switch Power Input Module Fuse Drawer Oven - Rear View Figure 2 - Location of the Fuse Drawer Page 8

19 Section 2 AQUATEST VA 2010 SERVICE DO NOT ATTEMPT TO SERVICE THIS PRODUCT YOURSELF, except as noted in this manual. If this instrument does not operate as described when the detailed operating instructions are followed, do not attempt to open or remove covers or make any adjustments not described in this manual. Attempting to service this unit yourself may expose you to dangerous voltage or other hazards and will void the warranty. Refer all servicing to authorized service personnel. DO NOT USE UNAUTHORIZED SUBSTITUTE REPLACEMENT PARTS. Be sure the service technician uses replacement parts specified by the manufacturer or having the same characteristics as the original part. Unauthorized substitutes may result in fire, electric shock, or other hazards and will void the warranty. Contact Photovolt Instruments to obtain proper return authorization before sending an instrument for repair. Photovolt is not responsible for instruments returned without proper authorization. For repair or service, please call , extension 259. Page 9

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21 Section 3 AQUATEST VA 2010 SECTION 3: SYSTEM DESCRIPTION INSPECTION OF PARTS The AQUATEST VA 2010 is delivered with the following standard accessories: (See the figures in this section to identify parts). Item Description Part Number 1 AQUATEST VA 2010 Main Unit AQUATEST VA 2010 Oven Unit Vaporizer Interface PC Board Vaporizer Interface Cable Vaporizer Power Input Cable Gas Line Desiccant Cartridge (filled) Platinum RTD Heated Transfer Line Gas Dispersion Tube way Vent Dryer Tube Magnet Pushrod Assembly Fittings Kit (4 pieces) Sample Boats (2) Boat Extraction Tool Polyurethane Gas Supply Tubing (6 ft) Teflon Gas Supply Tube Installation Manual Warranty Card Table 2 Standard Accessories VA 2010 MAIN UNIT The Vaporizer Main Unit holds the loader mechanism, gas flow controls, electronic interface board, and a display. The rear and top views are shown in Figure 3 and Figure 4. Page 11

22 AQUATEST VA 2010 Section Figure 3 - AQUATEST VA 2010 Rear View (1) Nitrogen In (2) Purge (3) Vaporizer I/F Cable Connector (4) Nitrogen Out (5) Vacuum Relief Valve (6) Desiccant Mounting Clamp (7) Serial Number Label Figure 4 - AQUATEST VA 2010 Top View (1) Power Indicator (2) Heater Demand Indicator (3) Gas Flow Indicator (4) Loader Position (5) Purge Valve Indicator (6) Gas Flow Regulator Valve (7) Oven Mounting Holes Page 12

23 Section 3 AQUATEST VA 2010 VA 2010 OVEN UNIT The Oven unit contains the electro-conductive glass (EC) that allows samples to be heated within a temperature range of 50 C to 300 C. Avoid touching the EC glass with bare hands. If it becomes necessary to handle the EC glass, wear clean cotton gloves. There is one electrical connection on the back of the Oven unit. The Vaporizer Power Input Cord connects to the matching 3-prong connector on the Vaporizer Interface PC Board. (see Figure 5). NOTE AC power is supplied to the Oven Module by the AQUATEST 2010 Titrator through the Power Input Cord. Do not connect the Oven Module directly to AC line voltage. Oven Pow er Connection Figure 5 - Oven Unit Showing Electrical Connection VAPORIZER STANDARD ACCESSORIES The standard accessories provided for use with the AQUATEST VA 2010 are shown in Figure 6 through Figure 15. Be sure to locate each of the components before discarding the packaging materials. Page 13

24 AQUATEST VA 2010 Section 3 Gas Dispersion Tube The Gas Dispersion tube is a glass tube, which is inserted into the vessel gas port to release the carrier gas below the surface of the vessel solution. It is designed to provide optimal extraction of moisture from the flowing gas stream. Sample Boats Figure 6 - Gas Dispersion Tube The Sample Boats are made from glass. They are inserted into the Main Oven Tube with the hook of the Pushrod inserted through the glass ring on one end of the boat. Samples are placed into the boats through the Main Oven Tube sample port and carried into the heated oven by the loader mechanism. Boats may be lined with aluminum foil to facilitate cleaning. 3-way Vent Tube Figure 7 - Sample Boats The 3-way Vent Tube replaces the Straight Vent Tube on the AQUATEST 2010 vessel. It allows the gas flow to be switched between venting through the desiccant or directly out of the vessel. Figure 8-3-way Vent Tube Page 14

25 Section 3 AQUATEST VA 2010 Main Oven Tube The Main Oven Tube is a glass chamber with a sample loading area, purge area, sample analysis area, and gas ports. The assembly includes a Glass Stopper, Oven Door, and Teflon-faced Door Seal. (When replacing the oven seal, position the glossy side toward the oven.) The Sample Boats are loaded into this chamber. Vaporizer Interface Cable Figure 9 - Main Oven Tube The Vaporizer Interface Cable carries the control signals from the AQUATEST 2010 Titrator to the Vaporizer Main Unit. One end of the cable attaches to the 15-pin connector on the Vaporizer Interface PC Board. The other end attaches to the 15-pin connector on the back of the Vaporizer Main Control Unit. Vaporizer Power Input Cord Figure 10 - Vaporizer Interface Cable An IEC type power cord is supplied with the AQUATEST 2010 Vaporizer. The cord is used to carry power from the Titrator to the Oven Unit. One end of the cord attaches to the IEC power outlet located on the Vaporizer Interface PC Board. The other end attaches to the IEC power inlet module on the back of the Oven Module. Page 15

26 AQUATEST VA 2010 Section 3 Pushrod Assembly The Pushrod Assembly is inserted into the Main Oven Tube with the free end of the wire inside of the glass ring on one end of a Sample Boat. When properly inserted, the Pushrod Assembly will cause the Sample Boat to move from the home position to the oven position during the Oven Diagnostic test. Sample Boat Pushrod Assembly Figure 11 - Pushrod Assembly (shown with Sample Boat) Desiccant Cartridge Assembly The Desiccant Cartridge Assembly is connected in the gas stream of the Vaporizer before it enters the oven tube. The molecular sieve in the Desiccant Cartridge removes trace levels of moisture that would increase the background moisture detected by the instrument. The desiccant should be changed regularly for proper operation of the AQUATEST 2010 Vaporizer System. (When the blue particles in the desiccant change to a much lighter blue than the cartridge cap, the desiccant should be changed.) Boat Extraction Tool Figure 12 - Desiccant Cartridge Assembly The Boat Extraction Tool is used to retrieve the Pushrod and Sample Boats from the Main Oven Tube. The Loader must be in the Home position before using the Extraction Tool to hook the eyelet on the magnet. Page 16

27 Section 3 AQUATEST VA 2010 Platinum RTD Figure 13 - Boat Extraction Tool The Platinum RTD measures the temperature at a point close to the middle of the oven. In order to prevent the occurrence of reactions between the RTD and components of the sample, it is encased in a glass sheath. The connector on the RTD can only be inserted into the socket on the back of the Vaporizer Interface PC Board in one orientation. Location of the sensor Gripping area for 6mm fitting Connector Figure 14 - Platinum RTD Vaporizer Interface PC Board The Vaporizer Interface PC Board allows the AQUATEST 2010 to communicate with and supply power to the Vaporizer. The AQUATEST 2010 can then control the loader mechanism, pneumatics, and heating function of the Vaporizer accessory during the analysis of a sample. P6 P7 P5 SW 1 TEMP HTR BLK GRN WHT 100VA C 200VA C - G + VA VA POWER Figure 15 - Vaporizer Interface PC Board Page 17

28 AQUATEST VA 2010 Section 3 The Interface PCB is shipped in an anti-static bag. NOTE Do not remove the Vaporizer Interface PCB from the anti-static bag until located in a static free environment (i.e. away from carpeting or other sources of static electricity). Static discharge to the PCB components will damage the circuit board. Retain the anti-static bag for future storage of the PCB. Fittings Kit The Fittings Kit contains two thumbscrews and two Teflon fittings. Use the thumbscrews to attach the Oven Assembly to the Main Control Unit. The 6 mm-to-6 mm Teflon fitting is used to hold the RTD in place on the Main Oven Tube. The 4 mmto-6 mm fitting is used to connect the Teflon Gas Supply Tube to the inlet port of the Main Oven Tube. Gas Line Tubing Standard accessories for the AQUATEST VA 2010 also includes two pieces of tubing. The short 4-mm Teflon tube is used to carry dry gas from the outlet of the Desiccant Cartridge to the inlet port of the Main Oven Tube. The 6-foot coil of polyurethane tubing is used to connect to the external gas supply. Page 18

29 Section 4 AQUATEST VA 2010 SECTION 4: INSTALLATION AND SETUP UNPACK THE VA 2010 THERMAL MOISTURE VAPORIZER SAVE AND STORE ALL PACKING MATERIALS IN CASE THE INSTRUMENT HAS TO BE RETURNED FOR REPAIR OR SERVICE.BE SURE ALL POWER IS TURNED OFF BEFORE MAKING ANY CONNECTIONS! Avoid dropping the components when removing them from the shipping packages. Be sure to remove all debris from the Oven assembly before use. INSTALL THE VAPORIZER INTERFACE PC BOARD The Vaporizer Interface PC Board must be installed in the back of the AQUATEST 2010 base unit. The Interface PC Board is installed by the following procedure: NOTE Installation of the Vaporizer Interface PCB should be performed in a staticfree environment (i.e. away from carpeting or other sources of static electricity). The installer and all tools should be grounded by touching the back of the AQUATEST 2010 chassis before removing the Interface PCB and during the installation. 1. Turn off the instrument power switch and unplug the AC Power Supply cord. 2. From the back of the instrument, locate the two crosshead (Phillips head) mounting screws that holds the blank plate in place (see Figure 16). 3. Remove the screws and the blank plate. Save the plate for future use if the Interface PC Board is to be removed from the instrument. 4. Verify that the Voltage Select toggle switch on the Interface PC Board is pointed toward the correct operating voltage (either 100V or 200V). (See.) 5. Carefully insert the Vaporizer Interface PC Board into the slot in the AQUATEST 2010 until the mounting plate is flat against the chassis. The edges of the Interface PC board should slide between the plastic guides located at the sides of the slot. 6. Press the PC board firmly in place so that the board's card edge contacts are fully inserted into the connectors located at the back of the slot on the AQUATEST Fix the PC board in place with the mounting screws that were removed from the blank plate. NOTE Be sure to use the mounting screws to fix the Interface PC board in place. The AQUATEST VA 2010 may not operate properly if the mounting screws are not used. Page 19

30 AQUATEST VA 2010 Section 4 Vaporizer Interface PCB Figure 16 - AQUATEST 2010 with Vaporizer I/F PCB installed. SET UP THE CONTROL UNIT Remove the Vaporizer Main Unit from the packing materials. The main unit sits on top of the recessed area toward the rear of the Titrator with the electrical and gas connections facing to the back. Connect one end of the Vaporizer Interface Cable to the 15-pin connector on the Vaporizer Interface PC Board. Connect the other end to the 15-pin connector on the back of the VA 2010 main unit. Be sure to tighten the fixing screws to prevent the cable from working loose. INSTALL THE DESICCANT CARTRIDGE The Desiccant Cartridge is delivered fully charged with an indicating moisture absorbent material. Do not remove the sealing plugs until you are ready to connect all of the gas flow lines to the instrument. 1. Remove the desiccant cartridge from its packing materials. 2. Remove the solid sealing plugs from the end connections. 3. The bottom plug (quick-connect fitting) is removed by pushing in on the plastic locking ring, while pulling on the plug. The top plug (Teflon elbow fitting) is removed by loosening the hex nut and pulling the plug out. Be sure to save the hex nut for installation of the gas line tubing. 4. The desiccant cartridge is pressed into the desiccant mounting clamp at the back of the Vaporizer Main Unit. See Figure 17 for proper orientation of the Desiccant Cartridge. Page 20

31 Section 4 AQUATEST VA 2010 Top Sealing Plug Direction of Gas flow Bottom Sealing Plug Figure 17 - Desiccant Cartridge CONNECT THE GAS SUPPLY LINES Polyurethane and Teflon tubing are used to make the gas connections at the back of the instrument. The polyurethane tubing is used for all connections located before the desiccant cartridge in the series. The Teflon tubing is used for all connections located after the desiccant cartridge. Using Quick-Connect Tubing Fittings Several of the gas supply tubes are connected to the system using quick-connect-tubing fittings. The tubing end must be clean, free of nicks or other surface scars and cut square and flat at the end. To attach a tube to the fitting, press the end of the tube firmly into the fitting until it bottoms out on the base of the fitting. Grasp the tubing and pull back until the fitting grabs it securely. NOTE The fitting does not seal to a gas tight connection until the tubing is securely seated by pulling back on the connection. If gas leaks are detected, be sure that the tubing end is not damaged. Cut off a short piece of the end if necessary. Pull back on each connection to ensure proper sealing. Page 21

32 AQUATEST VA 2010 Section 4 To remove the tubing from the fitting, press the blue or red plastic ring so that it is flush to the body of the fitting and pull back on the tubing Using Threaded Teflon Tubing Fittings Connections between gas line tubing and glass tubes employ threaded Teflon tubing fittings. Polyurethane or Teflon tubing ends must be clean, free of nicks or other surface scars and cut square and flat at the end. Glass tubes must be clean and free of surface chips or other irregularities. To attach a tube to the fitting, remove the hexagonal nut and place it on to the end of the tubing with the threaded portion facing the end of the tube. Press the end of the tube firmly into the fitting until it bottoms out on the base of the fitting. Carefully thread the hexagonal nut onto the fitting until it begins to tighten. Turn the hexagonal nut ½ turn past finger tight to seal the joint. Do not over-tighten the nut. Over-tightening can cause the tubing to collapse, blocking gas flow. Nitrogen In Connect one end of the 6-foot length of polyurethane tubing to your gas supply. Press the other end of the tubing firmly into the connection marked "N 2 In" on the back of the Vaporizer Main Unit. Fully insert the tube, and then lock it into place by pulling back slightly. NOTE Set the inlet pressure to a gauge pressure of 30-psi (2 kg/cm 2 ). Do not exceed a pressure of 35-psi (2.5 kg/cm 2 ). Excessive pressures may cause some gas connections to loosen, leak, or burst. Valve and Desiccant Connection Gas flow tubing must be routed through the vacuum relief valve and to the desiccant cartridge. 1. Press one end of the shortest piece of polyurethane tubing into the connection labeled "N 2 Out" on the back of the Vaporizer. 2. Connect the other end of the tube to the left side (outlet) of the 3-way vacuum relief valve. This connection has usually been completed on all new instruments. 3. Connect one end of the medium length piece of polyurethane tubing to the right side (inlet) of the 3-way vacuum relief valve. 4. Connect the other end to the bottom fitting on the desiccant cartridge. This tubing is usually connected to the vacuum relief valve on new instruments. 5. Use the hex nut to connect the Teflon tube from the Fittings Kit to the top fitting on the desiccant cartridge. 6. Attach the 4-mm side of one of the 4 mm-to-6 mm reducing unions to the other end of the Teflon tube. Page 22

33 Section 4 AQUATEST VA 2010 Purge Line Connection Press one end of the longer piece of Teflon tubing into the fitting marked "Purge" on the back of the Vaporizer. Pull back on the tubing to seal it in place. Attach the 4-mm side of the second 4 mm-to-6 mm reducing union to the other end (this step has usually been completed on new instruments). The reducing unions will be connected to the Main Oven Tube after installation of the Oven unit. ATTACH THE OVEN MODULE NOTE The AQUATEST VA 2010 is shipped without the Oven Module fuses installed. The fuses are located in a bag attached to the Oven Module. 1. Remove the two fuses from the bag attached to the Oven Module. 2. Locate the fuse drawer on the back of the Oven Module (see Figure 2). 3. Press down on the release tab on the fuse drawer to release the drawer. 4. Install the two fuses in the fuse drawer. 5. Replace the fuse drawer in the Oven Module and securely lock it in place. 6. Align the two threaded holes in the left side of the Oven Module with the holes in the lip on the chassis. 7. Fix the Oven Module in place with the two thumbscrews from the Fitting Kit. 8. Insert the IEC style Vaporizer Power Input Cord into the matching connector on the back of the Oven Module and Vaporizer Interface PC Board. INSTALL THE MAIN OVEN TUBE The Main Oven tube must be installed carefully into the VA It is held in place by a clamp attached to the side of the Oven Module. 1. Remove the sample port stopper from the Main Oven Tube. Loosen the clamp on the Oven unit until the Main Oven Tube will slide easily into place. Tighten the clamp so that the tube does not slide out of position easily. 2. Attach the 6-mm end of the reducing union from the desiccant cartridge to the gas inlet port in the middle of the Main Oven Tube. 3. Attach the 6-mm end of the reducing union from the "Purge" connection to the gas port on the right side of the Main Oven Tube. 4. Align tube so that the sample port is vertical and the gas inlet port sits in the rounded portion of the Vaporizer case. Page 23

34 AQUATEST VA 2010 Section 4 ATTACH THE PLATINUM RTD The Platinum RTD must be installed so that the tip of the sensor is located over the center of the sample boat when it is in the Oven position. The connection does not have to be airtight since there is no gas flow through this path. 1. Insert the Platinum RTD into one end of the 6 mm Teflon union from the fitting kit and fix it in place with the hex nut. 2. Place the other hex nut onto the upper port on the end of the Main Oven Tube. 3. Carefully insert the RTD into the upper port until the fitting butts firmly against the glass (see Figure 18). 4. Tighten the hex nuts so that the RTD is held in place. Do not over tighten the fitting. 5. Attach the three-prong connector to the TEMP receptacle on the Vaporizer Interface PC Board. The connector can be inserted in only one orientation. ATTACH THE HEATED TRANSFER LINE The Heated Transfer Live carries the moisture from the sample into the titration vessel. The sheath covering the Teflon tube is maintained at a temperature of 105 C to prevent condensation of the moisture. 1. Attach the 3-mm end of one of the 3 mm-to-6 mm Teflon reducing unions to each end of the Teflon tube inserted into the Heated Transfer Line and fix it in place with a 3-mm hex nut. (The fittings are usually attached to a new Heated Transfer Line.) Do not overtighten the fittings. 2. Place a 6-mm hex nut onto the Gas Dispersion Tube and attach the transfer line and fitting. 3. Place a 6-mm hex nut onto the lower port on the end of the Main Oven Tube and remaining end of the transfer line as shown in the diagram below. 4. Insert the 2-prong connector into the receptacle on the Vaporizer Interface PC Board. 1 2 Figure 18 - Platinum RTD and Heated Transfer Line Installation (1) Platinum RTD (2) Heated Transfer Line Page 24

35 Section 4 AQUATEST VA 2010 INSTALL THE 3-WAY VENT TUBE Fill the 3-way Vent Tube with silica gel desiccant. A plug of glass wool may be placed under and over the Silica gel. Replace the straight Vent Tube on the vessel with the 3- Way Vent Tube. Turn the stopcock to the correct operating position (see Figure 19). for Vaporizer for Direct Injection Figure 19 - Use of the 3-Way Vent Tube INSERT THE LOADER PUSHROD AND SAMPLE BOATS The Sample Boats can be lined with aluminum foil if the samples to be analyzed cannot be cleaned off the glass easily. Be sure to maintain a flat bottom on the boats. Do not cover the flattened bottom of the boat with foil. 1. Make sure that the boat loader is in the home position. If necessary, turn the instrument off then back on to automatically initialize the position of the loader. Alternatively, the loader can be operated manually with the boat extraction tools. 2. Remove the end cap from the Main Oven Tube. 3. Insert the boat into the Main Oven Tube so that the eyelet remains on the outside of the tube. Insert the hook on the pushrod through the eyelet and push the assembly into the oven tube until it is grasped by the loader magnet. Use the Boat Extraction Tool to insert the pushrod into the Oven Tube if necessary. 4. Replace the oven end cap. (The oven end cap seal should have the shiny side toward the oven.) Page 25

36 AQUATEST VA 2010 Section 4 CONNECT THE GAS DISPERSION TUBE The Gas Dispersion Tube must be inserted into the lower of the two vertical 15 mm ports on the vessel. This assures that all of the transferred moisture can be absorbed from the flowing gas. 1. Remove the solid stopper from the gas port on the vessel. 2. Lubricate the ground glass joint on the Gas Dispersion Tube with the sealing grease. 3. Insert it into the port. 4. The vessel may need to be rotated so that the Heated Transfer Line is not severely bent while connected between the Main Oven Tube and Vessel. 5. When properly installed, a steady stream of bubbles should be observed from the tip of the Gas Dispersion tube when the flow path is into the vessel. The gas should stop flowing when the path is through the purge valve. OPERATING THE AQUATEST VA 2010 Refer to the AQUATEST 2010 Titrator Instruction Manual for detailed operating procedures for the system. The Vaporizer should be preconditioned by following the blank reduction procedure before starting sample analysis. An abbreviated operating procedure is given in the following section. Page 26

37 Section 5 AQUATEST VA 2010 SECTION 5: PREPARING FOR OPERATION VAPORIZER DISPLAY The status of each component of the Vaporizer is indicated through the AQUATEST 2010 keypad and the Vaporizer display. The meaning of the status lights are given in the table below. Display Text "READY" "HEATER" "GAS FLOW" "LOADER" "VALVE" Description Of Function Lamp is illuminated when power is supplied to the Vaporizer. Heater demand indicator for the Oven. When illuminated, Oven is heating. Blinking light indicates that the Oven requires power. Lamp is illuminated when the detected gas flow is 100 ml/min or greater. Illuminated arrows indicate the direction of travel of the sample boat. Indicates the status of the purge valve. When illuminated the purge valve is open. The gas flow is through the purge path. When not illuminated, the gas flow is through the vessel. Table 3 - Vaporizer Status Indicators LOADER TEST Proper operation of the sample loader mechanism can be verified through the following procedure: 1. Press [OVEN] on the AQUATEST 2010 Titrator keypad. MOVE BOAT will be displayed. 2. Press the left arrow [ ] key to move the sample boat into the Oven. Check for smooth movement. The final position of the boat should be directly under the Platinum RTD as shown in Figure Press the right arrow [ ] key to move the boat to the home (sample loading) position. The final position of the boat should be directly under the sample loading port as shown in Figure 21. Page 27

38 AQUATEST VA 2010 Section 5 Figure 20 - Sample Boat Oven Position Figure 21 - Sample Boat Home Position If the boat movement is not smooth, the inside surface of the Main Oven Tube may require cleaning. SETTING GAS FLOW Dry nitrogen should be supplied to the instrument at an inlet pressure of 30 psi (2kg/cm 2 ). The flow rate of the carrier gas is adjusted by the following procedure: 1. Turn the handle on the Vacuum Relief Valve to the operating position so that the gas is allowed to flow through the Oven. The control knob should be horizontal (see Figure 24). 2. Turn the Gas Flow Regulator Valve knob fully clockwise (see Figure 4). Do not overtighten. 3. While observing the display on the Titrator, slowly open the flow control knob until the gas flow arrow indicates the proper flow rate for operation. A flow of 200 ml/min is recommended for most samples. Gas flow must be steady. Page 28

39 Section 5 AQUATEST VA The gas flow indicator is displayed on the AQUATEST 2010 LCD (see Figure 22). When the inlet pressure is set at a gauge pressure of 30 psi (2 kg/cm 2 ), the indicator will display the flow rate as follows: Figure 22 - AQUATEST VA 2010 Gas Flow Rate Indicator 5. Press the [VALVE] key on the Vaporizer keypad. The gas flow should be diverted between the titration vessel and the purge port each time the key is pressed. 6. If a steady stream of bubbles is not observed when the VALVE light is off, check the system for leaks. 7. Allow the gas to bubble through the vessel for the following steps. Vacuum Relief Valve Vent Position Figure 23-3-Way Vacuum Relief Valve Vent Position Vacuum Relief Valve Operating Position Figure 24-3-Way Vacuum Relief Valve Operating Position Page 29

40 AQUATEST VA 2010 Section 5 SETTING THE OVEN TEMPERATURE The AQUATEST 2010 Vaporizer can maintain oven temperatures of 50 C to 300 C under normal operating conditions. The Oven temperature is set through the AQUATEST 2010 keypad as are all other Vaporizer parameters. To set the Oven temperature: NOTE Verify that the Platinum RTD temperature probe is inserted into the Oven prior to applying power to prevent the thermal fuse from blowing. 1. Press [OVEN] twice. This will bypass the manual boat-movement feature. The display will read: OVEN TEMP: 2. If an Oven temperature was previously set, its value will be shown immediately after the colon. 3. To modify the temperature, use the number keys to type the value in degrees Celsius and press [ENTER]. 4. The Oven will begin to heat up to the new temperature within a few minutes. 5. When installing a new Vaporizer or after cleaning the Main Oven Tube, set a temperature of at least 200 C (392 F). Maintain this temperature while bringing the Titrator to set point as described in the AQUATEST 2010 operator's manual. NOTE The Heated Transfer Line is always maintained at an approximate temperature of 105 C (221 F). Page 30

41 Section 6 AQUATEST VA 2010 SECTION 6: OPERATION OF THE VAPORIZER ACCESSORY The AQUATEST 2010 Vaporizer accessory is controlled by the AQUATEST 2010 Titrator. For detailed operating instructions of the system, refer to Section 12.0 of the AQUATEST 2010 Installation and Instruction Manual. BLANK REDUCTION PROCEDURE The Vaporizer will normally have a background level of moisture in the gas lines and components when newly set up or when the desiccant cartridge is recharged. Use the following procedure to eliminate the moisture from the system. Low blanks are important when analyzing samples that contain trace amounts of moisture. 1. Place a sample boat into the Main Oven Tube and use the [OVEN] and left arrow [<] keys to move the boat into the Oven. Wait until the Oven reaches a temperature of at least 100 C. 2. Press the [VALVE] key on the Vaporizer display to illuminate the lamp. 3. Turn the 3-Way Vacuum Relief Valve handle to the horizontal position. Adjust the gas flow to about 200 ml/min. 4. Move the 3-way stopcock on the Vent Tube so that the gas will flow through the desiccant. 5. Wait for a period of 5 to 10 minutes for the moisture in the gas train to be removed. 6. Press the [VALVE] key so that the lamp goes off. The gas flow will be diverted to the titration cell. Turn the 3-way stopcock on the Vent Tube so that the gas flows through the open port. 7. Follow the procedure for bringing the AQUATEST 2010 to set point as described in the AQUATEST 2010 operator's manual. 8. When the titration rate drops below 0.1 µg/sec, press the right arrow [>] key to move the boat to the load position. 9. Allow the boat to cool before beginning sample analysis. If the titration rate rises after this procedure, check the gas lines for leaks and check the condition of the molecular sieve in the desiccant cartridge. 10. Correct any problems and repeat the procedure. Page 31

42 AQUATEST VA 2010 Section 6 SHUTTING DOWN THE VAPORIZER The Vaporizer can remain attached to the AQUATEST 2010 when samples are to be analyzed by the direct method. The gas flow and oven power should be turned off to conserve both. 1. Press the [OVEN] key twice. The preset oven temperature will be displayed. 2. Press the [CLEAR] key to clear the Oven temperature. Press the [ENTER] key to begin cooling the Oven. The display will return to the Main menu. 3. Move the 3-Way Vacuum Relief Valve handle to the vertical position to relieve the vacuum that forms when the Oven cools. Loosen the Oven End Cap. 4. Shut off the gas supply at the source. NOTE The Flow Regulation valve is not intended to be used as a gas shut off valve. Do not overtighten the knob. If the gas supply cannot be shut off at the supply source, then a shut off valve should be plumbed into the supply line. 5. Turn the 3-way stopcock on the Vent Tube so that the vessel atmosphere will be vented through the desiccant. Alternatively, the 3-Way Vent Tube can be replaced by the Straight Vent Tube. 6. If samples are to be analyzed on the AQUATEST 2010 by the direct method, remove the Gas Dispersion Tube and insert the solid stopper in its place. 7. If the instrument will not be operated, the Gas Dispersion Tube can remain in the Vessel. 8. Empty the Sample Boat. The boat can be stored in the Main Oven Tube. Page 32

43 Section 7 AQUATEST VA 2010 SECTION 7: MAINTENANCE GENERAL MAINTENANCE The AQUATEST 2010 Vaporizer has been designed to provide years of operation under the rigors of normal laboratory use. The appearance and operation of your instrument can be enhanced through a routine of basic maintenance. 1. Spills of reagent or sample on the outer surface of the case should be cleaned up quickly using a slightly damp cloth. In case of a large spill, immediately unplug the instrument until the excess liquid can be removed. 2. Inspect the instrument regularly for signs of wear. Most problems with obtaining the correct test result can be traced to a leak in the gas flow system. If an analysis of a known standard gives low results, check each connection in the flow system for signs of leakage. 3. Periodically inspect consumable components such as the Oven Door Seal for signs of wear (replacement part number ). GAS LINE DESICCANT The molecular sieve desiccant in the gas-line dryer-cartridge must be changed periodically. The dark blue beads are a moisture indicating silica gel. When there is a noticeable color change in the indicating beads, the cartridge should be emptied and filled with fresh desiccant. In some cases, the background on the AQUATEST 2010 may raise before a color change occurs to the indicating desiccant. Replace the desiccant if the background is sustained at a level greater than 0.3 µg/sec (replacement part number ). Replace the desiccant by the following procedure: 1. Remove the polyurethane tube from the bottom of the cartridge by pushing the lock collar in while pulling on the tubing. 2. The cartridge can now be turned upside down and the metal end cap removed. 3. Pour the old desiccant into an appropriate container. 4. Replace the glass wool in the top of the tube. 5. Pour enough fresh desiccant to completely fill the cartridge. 6. Place a pad of glass wool in the bottom cap and attach it to the cartridge. 7. Place the filled cartridge into the mounting clamp and reattach the polyurethane supply line. 8. Follow the blank reduction procedure in Section 6 of this manual before resuming sample analysis. Page 33