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SFA SA3000-5000D Newpump
SFA SA3000-5000D Newpump
SFA SA3000-5000D Newpump
USER MANUAL
SEGMENTED FLOW ANALYZER
SA3000/5000 CHEMISTRY UNIT
USER MANUAL
This manual guides you through the complete definition of the chemistry unit, to help
you quickly gain the necessary knowledge and confidence to use the chemistry unit
to its optimum efficiency.
If despite the information given in this manual, any problems should arise, please do
not hesitate to call your local Skalar representative or the Skalar head office at the
address given below.
1 INTRODUCTION
The samples coming from a sampler and the reagents from the canisters are drawn
to the chemistry unit by the multi-speed pump. The built-in air-injector provides air
segmentation of the samples. On the chemistry module the required reagents are
added to the samples and mixed in coils. Special in-line treatments of the reaction
mixtures are possible: UV digestion, distillation, hydrolysis, dialysis, ion-
exchange/reduction, heating and cooling. The reaction mixtures are subsequently
transferred to the built-in detection heads or separate external detectors (depending
on the chemistry to be measured). After detection the reaction mixture is transferred
to a waste receptacle, which must be connected to a waste facility. The measured
signals are collected on a computer, where the data are processed.
SA3000/5000 Chemistry unit Chapter 1 Introduction 1-2
The multi-speed pump with standby, analysis and fast rinse position takes care for a
fast start-up and shutdown of the analyzer by pumping the reagents or rinsing
solution at an elevated speed.
For chemistries that need reactors (which are placed under the chemistry module
plate), these reactors are connected to reactor controllers with clearly visible
temperature displays, which are integrated at the front and/or the back of the pump in
the chemistry unit.
For chemistries with in-line distillation a back panel is integrated on the chemistry
unit.
Leak detectors are placed at the bottom of the chemistry unit. When a system
controller is present and a leak is detected, the system will shut down.
The chemistry can be built-up from left to right as well as from right to left (see Figure
1.2), which is an advantage (it keeps the sampling lines short and ease maintenance)
when more chemistry channels are to be run simultaneously on a second
SA3000/5000 chemistry unit.
The chemistry unit can be run fully automatic in combination with a SA1050, SA1074
or SA1077 autosampler, electrical reagent valves, system controller and
FlowAccessTM software.
The SA3000 and SA5000 are identical chemistry units, except for the proportioning
pump. The pump of the SA3000 is provided with one pump deck and roller cage that
is equipped for 16 pump tubing’s, while the SA5000 is provided with a pump with two
pump decks and roller cages and is equipped for 32 pump tubing’s.
Figure 1.2 Example of system with SA1074 sampler and two chemistry units
SA3000/5000 Chemistry unit Chapter 1 Introduction 1-3
Only qualified personnel should carry out repair of the exposed equipment.
2. Before the instrument is connected to the mains and switched on, check whether
the required voltage (indicated on the type plate at the back of the instrument)
corresponds with the line voltage.
3. The instrument power cord must only be plugged into a line supply outlet with
ground protector (earth). If an extension cord is used, make sure that the protector
line is not interrupted.
4. Opening of the instrument or disassembling of parts of the instrument can set free
voltage carrying parts while the instrument is connected to the mains. Also
connectors could carry voltage. Before any service, repair or change of parts, the
instrument has to be disconnected from all power supplies. Service and repair
work on voltage carrying open instruments should be avoided whenever possible.
If such work is absolutely necessary, qualified personnel, who are aware of the
hazards of this work, should carry it out.
5. Whenever it is likely that safe operation is impaired, the instrument must be made
inoperative and secured against unintended operation. The appropriate servicing
personnel must then be informed.
6. The instrument must be disconnected from all electrical sources when a fuse is to
be replaced.
7. Keep the chemistry unit and all incorporated components dry and clean.
8. Keep hands, jewelry, hair etc. from the inside of the instrument whenever it is in
operation.
Skalar Analytical B.V. does not accept liability for any consequences caused by
irresponsible use or irresponsible handling of the chemistry unit, nor for the effects
and consequences induced by its use.
SA3000/5000 Chemistry unit Chapter 1 Introduction 1-5
Distributor:
Company name:
Address:
Post code/ZIP
City
Country:
Contact person:
Telephone number:
Fax number:
E-mail address:
Company stamp:
Name:
Signature:
The warranty registration form will only be valid when accompanied by the signed
customer acceptance form.
Please return this form to: SKALAR ANALYTICAL B.V.
PO Box 3237
4800 DE Breda
The Netherlands
Attn.: Service desk
Date:
SA3000/5000 Chemistry unit Chapter 1 Introduction 1-7
Company name:
Address:
Post code/ZIP code:
City:
Country:
Date:
The undersigned authorized officer confirms that the performance of the instrument,
as per the purchase order number as mentioned on the warranty registration form, is
according to the specifications as submitted by the manufacturer.
YES
NO
Remarks:
Signature
Name
SA3000/5000 Chemistry unit Chapter 2 Unpacking and installation 2-1
2.4 Installation
Important notes:
• Connect the power cables only after all other connections have been made.
• All cables and tubing to be connected should be labeled.
• Use lubricant for tubing-tubing and glass-tubing connections if necessary, except
for connections on the TOC module.
• Do not use lubricant for connections on Perspex manifolds and heat exchangers.
Here the installation of a complete analyzer system is described. You can skip the
instructions for the parts that are not included in your analyzer system.
Procedure: (Skip an instruction if the item is not present)
1. Place the sampler on the left side of the available bench space. Check if the
voltage selector on the sampler is set on the proper voltage and for the SA1000
check if 50 or 60 Hz is used. Adjust if necessary.
2. Connect the supplied RS232 cable (not for SA1000 sampler) and power cable to
the sampler.
3. Place the chemistry unit right from the sampler; place the (optional) rinsing valves
between the sampler and the chemistry unit. Save if possible enough space for
the reagents (and the water bath*, if present) between sampler and chemistry
unit. (If not enough space is available on the bench, place the reagents (and
water bath) under the bench, but as high as possible to reduce the backpressure
and to keep the reagent lines as short as possible).
* A water bath may not be placed beside the electronics (interface, detectors, etc.)
4. Place the (optional) air scrubber at the back of the analyzer.
5. Lead the tubing from the water bath under the back door of the chemistry unit till
under the chemistry module. Lift the module and connect the tubing to the heat
exchanger. Fill the water bath (preferably with distilled water) until about 2 cm
under the cover plate. Place the thermometer.
6. Connect the power cable and (optional, only if a system controller is present) the
system controller cable (9-p sub D connector) to the back of the chemistry unit.
Connect the tubing of the air scrubber to the air inlet at the back of the instrument.
Optional: Connect the cable for connection to a second SA5000 chemistry unit
and/or the system controller socket bench(es)(only in combination with SA8505
interface) to the required connection(s). Each type of device requires its own
socket bench (pumps, heaters, detectors).
7. Place the back panel with the distillation unit (and flow meter) in the holes on the
back panel of the chemistry unit.
8. Connect the inlet (lower connection) of the flow meter to a nitrogen gas cylinder.
Connect the inlet of the distillation unit to the outlet (upper connection) of the flow
meter.
9. Place the measuring heads as required for the application in the chemistry unit.
Open the right side door in the chemistry unit and connect the connection cables
to the measuring heads. Close the door with the cables led outside at the bottom
of the door. For a measurement with the SA6280, SA6310 or SA6850 no
measuring head is placed in the chemistry unit. For these measurements the
detection head is situated on its electronics section.
SA3000/5000 Chemistry unit Chapter 2 Unpacking and installation 2-4
10. Place the electronics housing of the analogue detector (SA6280 IR detector,
SA6310 Fluorimeter, SA6850 UV detector, etc.) at the right of the chemistry unit.
11. Place the interface (SA8502, SA8503 or SA8505) right from the photometer unit.
Connect the RS232 cable coming from the sampler to the required RS232
connection on the interface. Also connect the RS232 cable for the connection to
the PC and the power cable on the interface. For SA8502 and SA8503: Connect
the (optional) system controller cable from the chemistry unit with the 9-p sub D
connector and leak detection plugs to the interface (system 1). Connect the
automatic rinsing valves (cat.no. 21530902-21530909) to the connections at
system 1 on the interface. If a system controller power bar is required, connect
this power bar to connector ‘System 2’ on the interface. For SA8505: Connect the
(optional) system controller cable from the chemistry unit with the 9-p sub D
connector plugs to the system controller bracket on the interface. Connect the
automatic rinsing valves (cat.no. 21530912-21530919) to the connections at the
system controller bracket on the interface.
12. Connect the cable(s) of the analogue detection head(s) to the electronics housing
and connect the output cables from the electronics housing to the required
channel connection on the interface (for SA8505 connect the cable to the correct
channel on the connection box, which is connected to the analog insert board on
the interface). Connect the power cable to the electronics section. Refer also to
the provided manuals of the interface and detector(s).
Remark: If a digital detector is present connect the cables of the detection heads
directly to the required channel on the interface. All connections on the
interface must be connected; otherwise the not connected PCB’s must be
removed from the interface.
13. Place the PC on the interface (SA8505 can also be placed upright; in this case
place the PC beside the interface) and the printer right from the interface.
Connect the connection cables between screen and PC and printer and PC.
Connect the RS232 cable coming from the interface. Connect the power cables
on PC, screen and printer.
18. If nitrogen is used for segmentation, connect the supply tubing from the gas
cylinder to the inlet at the backside of the chemistry unit. If a distillation unit is
present use a T-piece.
19. Place the interference filters in the measuring head(s). Refer to the method sheet
for the required filter.
20. Place the required flow cell (refer to the corresponding method sheet) and
connect the tubing to the flow cell (for proper connection see the manual for the
SA62xx or interface).
21. Place the waste tubing, coming from the waste receptacles in the chemistry unit
and from the rinsing vessel on the sampler, in a waste container(s). See also
chapter 2.2.
22. Place the rinsing water supply tubing (check the labeling) on the sampler and the
reagent supply tubing (to the valves) in distilled water.
23. Connect the power cables of the sampler, the chemistry unit, the interface, the PC
and printer to the mains. Connect all other power cables to the mains, or to the
required part of the system controller power bar, if required.
24. Now first the chemistry unit is checked.
25. Slightly grease the pump decks and close them.
26. If nitrogen is used, turn on the gas supply; adjust the pressure valve on the bottle
until it indicates 0.9 -1 bar (90 - 100 kPa).
27. If a column is present on the module, by-pass it from the stream by turning the tap
on the module.
28. Lift the air bars by their rings and turn them counter clockwise, then release the
rings to place the bars square over the air tubing.
29. Switch on the sampler and the chemistry unit only. (If the reactor control units are
on, switch them off, see chapter 4.6). The pump starts in normal mode.
30. Let the system run during 30 minutes with distilled water on low, normal and high
speed (use the switch at the front of the chemistry unit) and check the system for
leaks. Repair any leaks found.
31. When everything is working satisfactory, switch off the sampler and the chemistry
unit.
Note: If the unit is not used anymore during the day, close the gas supply and open
the pump decks.
32. The installation is continued with the installation of the software. Switch on the PC
and let Windows start up.
33. Install the FlowAccessTM software. Refer to the installation instructions.
34. Copy the supplied .mdb file with the system setup into the FlowAccessTM
directory.
35. To run an analysis refer to the manuals supplied with the system.
SA3000/5000 Chemistry unit Chapter 3 Maintenance 3-1
3 MAINTENANCE
3.1 Scheduled maintenance
The following preventative maintenance procedures are recommended to assure
continued reliable operation of the Skalar Flow Analyzer system.
A. Daily:
1. Check all tubing for loose connections and leaks.
2. Check the reagents and standards, prepare new if required (see method sheets).
3. Perform the rinsing procedure as recommended for the method at the end of the
operation.
4. Clean all spillage with a water-dampened cloth. If it is necessary to use a cleaning
solution, first check the method for possible interaction with the reagents in use.
5. At the end of the operations, release the pump decks. If the system will be off for
more than 48 hours, lift the air bars and turn them anti clockwise until the air
tubing are released. This prevents premature occluding of the tubes.
Note: The pump decks cannot be lifted if the ‘Time program’ is used in the software.
B. Weekly
1. Check the reagent absorbance and primer sensitivity at least every week or
whenever a new reagent or standard is used. Check the values obtained against
previously obtained values.
2. Check if the pump decks at the inside contain a thin film of grease. Smoothen a
fingertip of grease over the full plate and remove any overdose at the edges.
3. While the pump is running, take each silicone air tubing on both sides of the air
injector and slide it slightly in either direction so that a new section is under the air
bars.
4. Clean the rinsing liquid vessel on the sampler with a syringe and check for dirt.
5. Check the sample tubing. Replace if clogged or dirty.
6. Check the sample needle by pricking through the needle. Replace if blocked.
7. Rinse the system as recommended in the method sheet.
C. Monthly
1. Use an alcohol-moisten cloth to wipe of the inside of the pump decks and then
grease the plate with new grease.
2. Replace the silicon air tubing (SA3150/SA5150) with new tubing, see chapter 3.2.
3. Shift all pump tubing one bridge or, if this was already done, replace the tubing
(see chapter 3.3). If the analyzer is not used daily for more than 5 hours, this
stretching or replacement can be done after 2 months.
4. Use a clean soft cloth to wipe the sample needle.
5. Clean the interference filter using lens tissue. Replace if delaminated.
6. Replace, if present, the dialysis membrane(s) (see chapter 3.5).
7. Remove the syringe from the diluter and clean the inside of the syringe after
removing the plunger with a soft brush and distilled water. If algae persist on the
wall and the plunger, clean with 1:10 diluted hypo chlorite solution and rinse then
thoroughly with distilled water.
SA3000/5000 Chemistry unit Chapter 3 Maintenance 3-2
D. 6 Monthly
1. Check the pump decks for wear every six months, or after 1000 hours of pumping
time, and replace if worn.
2. Check the pump rollers and clean with a dry soft clean cloth.
3. If applicable, replace the CO2 absorbent cartridge.
E. Yearly
1. Replace the halogen detector lamp yearly, or after 3500 hours of use.
2. Check the interference filters if they are dark around the edges. If so, replace
them.
3. Clean all coils, waste vessels, glass tubing, distillation unit, flow cells and Perspex
manifolds and replace all tubing as described in chapter 3.2, 3.3, 3.4 and 3.5.
For replacement procedures in the optional equipment see their respective manuals.
5. Loosen the first pump tubing from the clamps and its connections.
6. Take a pump tubing of the same size and make a connection with the supply
tubing or the valve. Use a sleeve if necessary. For the connection with the valve a
piece of SA3035 tubing is used for pump tubing smaller than SA3032. Use a little
lubricant.
7. Place the bridges on the clamps, leaving the extra bridge at the side of the
sampler.
8. Connect the pump tubing to the manifold.
9. Repeat step 5 – 8 for all pump tubing.
10. Slightly grease the pump deck(s) and replace the decks.
11. Close the decks by pushing them down while pulling the locking pins together
until the pins can lock the deck. The clamp is pushed down with the deck, thus
stretching the pump tubing on the roller cage. Lower the handle.
Figure 3.6
SA3000/5000 Chemistry unit Chapter 3 Maintenance 3-5
Figure 3.7
Figure 3.8
Tubing-glass connection:
A tubing-glass connection is made when connecting a tubing to a coil. The ID of the
coil is the same as the ID of the tube. The OD’s however differ and so an extra
sleeve is used to connect them (see Figure 3.9).
1. Slide a piece of SA 5401
(2.4 mm ID) sleeve over
the SA 5142 (1.5 mm ID)
tubing; use some lubricant
to ease the sliding.
2. Cut off straight the tubing,
so that the sleeve has the
length of one centimeter.
3. Then take a piece of 2 cm
of SA 5400 (3.2 mm ID) Figure 3.9
sleeve, slide one end over
the sleeve just made and
the other end over the end
of the glass coil.
Glass-glass connection:
1. Make sure that the glass Figure 3.10
ends are touching each
other and the connection is the center of the sleeve (see Figure 3.10).
2. Use SA 5400 for all glass-glass connections except for reactors (use SA 5192
acidflex) and distillation units (use SA 5194 acidflex).
SA3000/5000 Chemistry unit Chapter 3 Maintenance 3-6
Warning: Only qualified personnel, who are aware of the hazards when working with
open equipment, should perform this work.
1. The membrane pump with air-reducing valve is located behind the front cover
with the On/Off switch and pump speed control (see Figure 3.12).
5. Then turn the knob (see right arrow in Figure 3.13) until the air bubbles are at the
size as required (size between 2 and 5 mm without the meniscus at both sides).
More pressure creates bigger air bubbles; less pressure smaller air bubbles.
6. When the air bubbles are at the required size, tighten the locking ring by turning it
clockwise (make sure not to turn the knob with it).
7. Close the front cover and replace and tighten the screw.
Figure 3.14
2. Gently lift off the top half of the
dialyzer and remove the old
membrane (see Figure 3.15).
Figure 3.18
8. Carefully position the dialyzer
top plate on the bottom plate
(see Figure 3.19).
4 TECHNICAL INFORMATION
4.1 Technical specifications
SA3000/5000
Material housing: Polypropylene
Housing: According CE and CSA regulations
Power supply: 100-240 V
Dimensions: 27 cm (H) x 54 cm (D) x 84 cm (W)
With integrated rack: 67 cm (H) x 54 cm (D) x 84 cm (W)
Weight: ± 25 kg
Power consumption: 650 VA max.
Fuses: 3.15 A (230 V), 6.3 A (115 V)
Capacity: 5 chemistry module positions
Waste: 5 separate glass waste receptacles
Detection: 4 positions for dual detection heads and 5 positions
for detection heads with matrix correction
Performance: Software controlled hardware on/off switching (with
system controller)
Safety: Leak detection (with system controller)
Air supply: Membrane pump with pressure regulator
External gas supply: 1 bar (100 kPa)
Air injector: Mechanical, dual bar
Capacity air injector: 10 channels
Injection: 30 air bubbles/min. at normal pump speed
Fan: 24 V DC
Reactor control: Built-in dual channel controllers, max. 2, if required
for the application(s) installed
Pump: Multi-speed (off, standby, normal, high)
Pump speed: 1 rpm. (standby), 6 rpm. (normal) and 10 rpm. (high)
Motor pump: Stepper motor
Pump decks: 2, fully removable*
Roller cage: 2 x 10 stainless steel rollers*
Capacity: 2 x 16 channels*
* SA3000 has the same specifications as model SA5000, except that the
proportioning pump is provided with 1 pump deck, 1 x 10 stainless steel rollers and 1
x 16 channels
SA3000/5000 Chemistry unit Chapter 4 Technical information 4-2
4.2 Housing
The chemistry unit consists of three compartments (see Figure 4.4).
• Compartment 1 houses the power supply board, the proportioning pump, the
membrane pump with air-reducing valve, the reactor control unit(s) and the
electronics for the reactor control unit(s) and pump.
• Compartment 2 houses the chemistry modules (up to five).
• Compartment 3 houses the detection heads and the waste receptacles.
In Compartment 1 the proportioning pump (4) is mounted on top of the bracket
above the electronic boards. The electronic boards are mounted upside down against
the bracket and can, if necessary, be reached from the bottom side after removing
the cover of the bracket. The multi-speed proportioning pump has two pump decks,
divided by the air injector and is provided with a drain to compartment 2 in the case
that the pump tubing are leaking. (The SA3000 has a pump with one pump deck).
The membrane pump with reducing valve for the air supply is placed just behind the
front cover (5, membrane pump not visible on Figure 4.4, see Figure 3.13).
In the front cover (see Figure 4.1), the On/Off switch and the speed selector for the
multi-speed proportioning pump is placed. Also a dual channel reactor control unit is
mounted here. If no reactors are present a blind plate covers the opening.
Figure 4.1 Front cover Figure 4.2 Back cover Figure 4.3
In the back cover (see Figure 4.2 and no. 6 in Figure 4.4) the power entry, the fan,
the connector (9-p sub-D) for the system controller, the reactor control unit (only if
more than two reactors are present on the chemistry modules), the air inlet and 4
mini DIN connectors for external connections are placed. When more than 4 reactors
and/or other devices (as UV digesters, analogue detectors and external pumps) are
present, and the system is equipped with a system controller, these devices are
connected to an external system controller power bar (cat. no. 28505940, see Figure
4.3), which is connected to the required DIN connector on the interface. Each type
requires its own socket bench. The DIN connector called ‘second CFA’ is used to
connect a second SA5000 chemistry unit to be controlled by the same system
controller (cable is connected to 9-p sub D on second chemistry unit).
SA3000/5000 Chemistry unit Chapter 4 Technical information 4-3
The Cross-sections of air-injector and pump are shown in Figure 4.6 and Figure 4.7.
Description Quantity
O-ring 4x1 Buna 1 pc.
Tubing silicone 0.5x2.5 mm Raumedic 1m
Tubing silicone 1.0x3.0 mm Raumedic 1m
Tubing PE 1.0x2.7 mm PT53E 1m
Tubing PE 1.5x2.7 mm PT54 1m
Tubing PE 0.5x2.5 mm PT50A 1m
Tubing FEP 1.0x2.0 mm 5m
SA3000/5000 Chemistry unit Index
INDEX
Interference filters ................................. 2-4
A Introduction ........................................... 1-1
Air ........................................................ 2-2 Ion-exchange/reduction.................. 1-1, 4-3
Air bars................................................. 2-5
Air injector .............................. 1-1, 4-2, 4-6 L
Air scrubber .......................................... 2-3 Laboratory requirements .... See Installation
Autosampler ......................................... 1-2 Leak detection ............................... 1-2, 2-4
Location ................................................ 2-1
B Lubricant ............................................... 2-3
Back panel .................................... 1-2, 2-3
M
C Maintenance ......................................... 3-1
Chemistry module ................................ 4-2 6 Monthly .......................................... 3-2
Chemistry modules............................... 1-1 Changing pre-mount membranes ...... 3-7
Chemistry unit ........................ 1-1, 2-2, 2-3 Changing the air tubing ..................... 3-2
Column .......................................... 2-5, 4-3 Daily .................................................. 3-1
Computer ............................................. 2-2 Dialyzer ............................................. 3-7
Computer screen .................................. 2-2 Monthly ............................................. 3-1
Consumables ....................................... 5-1 Replacing the pump deck springs ..... 3-6
Cooling ................................................. 1-1 Replacing the pump tubing................ 3-2
Customer acceptance .......................... 1-7 Scheduled ......................................... 3-1
Stretching the pump tubing ............... 3-2
D Tubing connections ........................... 3-4
Damage ............................................... 2-1 Weekly .............................................. 3-1
Detection .............................................. 1-1 Yearly................................................ 3-2
Detection head ....................... 2-3, 4-2, 4-3 Matrix correction ................................... 4-3
Dialysis ................................................. 1-1 Membrane pump ............................ 4-2, 4-6
Dialyzer ................................................ 4-3 Method sheet ........................................ 2-4
Digital detector ..................................... 2-4 Multi-speed pump ............ 1-1, 1-2, 4-2, 4-4
Distillation ...................................... 1-1, 2-3
N
F Nitrogen .................................. 2-2, 2-4, 4-6
Flow cell ............................................... 2-5 Normal speed ....................................... 4-5
FlowAccessTM ................................ 1-2, 2-5
Fuses ................................................... 2-2 P
PC ........................................................ 2-4
G Perspex manifold .................................. 2-3
Gas-reducing valve ....................... 2-2, 2-5 Power consumption .............................. 2-2
Grease ................................................. 3-1 Power supply ........................................ 2-2
Printer ............................................ 2-2, 2-4
H Proportioning pump................. 4-2, 4-4, 4-6
Heat exchanger ............................. 2-3, 4-3 Pump deck ..................................... 2-5, 4-4
Heating ................................................. 1-1 Pump speed.......................................... 4-5
High speed ........................................... 4-5 Pump tubing................................... 2-4, 4-4
Hydrolysis............................................. 1-1
R
I Reactor .......................................... 4-3, 4-7
Installation ..................................... 2-1, 2-3 Reactor control
Instrument requirements ................... 2-2 Adjusment ......................................... 4-8
Laboratory requirements................... 2-1 Error messages................................. 4-8
Instrument requirements.... See Installation Reactor controller............. 1-2, 2-5, 4-2, 4-7
Interface ........................................ 2-2, 2-4 Reactors ............................................... 1-2
SA3000/5000 Chemistry unit Index