BWB Lithium Service Manual
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BWB Lithium Service Manual

Flame photometer range
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BWB
FLAME PHOTOMETER RANGE
SERVICE MANUAL
Firmware 4.0 on
Version G4.01

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  • Page 1 FLAME PHOTOMETER RANGE SERVICE MANUAL Firmware 4.0 on Version G4.01...
  • Page 2 www.bwbcustomerportal.com * Due to launch mid 2021...
  • Page 3 Ensure you read this manual cover to cover before attempting to use the instrument. Analytical instrumentation is very sensitive and BWB Technologies Ltd will not be held responsible for operators failing to follow correct processes. This manual has been written in English, any translations have been conducted at the discretion of the distributor or importer. The English version will always take precedence where required.

  • Page 4: Table Of Contents

    CONTENTS Safety ..........Gas flow schematic.
  • Page 5 CONTENTS Upgrading to ‘AFHS’ enabled......Upgrading (installing) the printer module....Upgrading to mA output functionality.

  • Page 7: Safety

    For full risk assessment information please refer to the separate Risk Assessment Document in Annex A. Please ensure you read this information carefully prior to installing or using a BWB Flame Photometer The instrument is designed to be operated only by trained In the event of a problem where the possibility of safety protection laboratory competent operators over the age of 18.

  • Page 8: Hazards

    Safety statements All electrical equipment is potentially hazardous. Never remove Under no circumstances should the instrument be installed beneath covers from the instrument unless specific maintenance overhanging cabinets. There must be at least 50cm of clear space procedures are being followed by trained personnel. above the chimney.

  • Page 9: Operational Recommendations

    Operational recommendations The Flame Photometer must be installed in a clean, draught-free Solutions should always be stored away from direct sunlight, environment, where a stable temperature can be maintained. and preferably at temperatures below 25˚C. Glass containers The instrument should also be sited away from bright sunlight should not be used for storage as these may lead to and other intense light sources, (away from doors, windows, fans contamination through sodium leaching into the solution.
  • Page 10 If this occurs, clean the outside of the tube with IPA or a similar de-greasing agent. Always use genuine BWB Technologies Ltd replacement parts and qualified personnel to carry out any work on the instrument. Always carry out maintenance when indicated or in line with your organisations standard operating procedures (SOPs) The front panel is impervious to many chemicals.

  • Page 11: Introduction

    Ensure the gas supply is turned off at source and the gas supply is disconnected. This Manual is intended to support all of the products in the BWB Flame Photometer range, these are: After servicing test all gas hose connections for leakage with a...

  • Page 12: Unboxing

    – this contains DI water and Remove the flame photometer Diluent Concentrate. Finally remove the document box from the bottom We strongly recommended you retain the packaging. Damage caused from returning the instrument in non-BWB packaging is billed at the normal rate.

  • Page 13: Front Panel Controls

    Front Panel Controls Display Status LEDs Warning LEDs Keypad Function Keys...

  • Page 14: Rear Panel Controls And Connections

    Rear panel controls and connections 1. Power Switch: Turns the power On/Off. 2. Power Inlet Socket: Receives the power cord from the mains. 3. Earth Stud 4. Comms: USB for computer connection. RS232 for connection to AFHS. 5. AFHS Low Level: Socket for the AFHS Reservoir (where fitted).

  • Page 15: Sample Area And Chimney

    Sample area & chimney Flame Inspection Port Outer Chimney Gas Flow Adjuster & Guard Mixing Chamber NOTE: adjustment is Retaining Clips made by turning the metal knob, not the Mixing Chamber black guard. Aspiration Nebuliser Retaining Tube Screw & Bracket Nebuliser Sample Drain Cup fitted...

  • Page 16: Installation

    A gas fuel supply of Propane, Butane, or Propane/Butane contaminants. mixture (as in LPG) is used on the BWB model range. It should • The instrument should not be stored beneath overhanging be regulated at the source to no more than 20Bar with a cupboards.
  • Page 17 Submission of the If an exterior alternate air source is desired, there is a hose report document to BWB results in certification for barb on the rear panel. The air source must be regulated to 10 performance and operation validation.

  • Page 18: The Set Up And Service Menu

    It is recommended that all 4 NA changes to set-up parameters are completed prior to calibration and undertaking sample analysis. BWB-XP: Indicates model parent (XP or BIO regardless of model type) 1>Clock 5 Extras IntRef=OFF: If your model supports Internal reference you can toggle 2 Rest Calib between the model specific parameters here (Li, Cs, Off).

  • Page 19: The Interface Menu

    The setup & service menu The interface menu 1>Ion Resolution 1>Config 5 Maint 2 Next Calib: ppm 2 Interfaces 3 Ions 4 Test Hardware 1>Na 1dp 5 Ba 1dp 1>LCD Contrast: 40 2 Setup Chart 3 Li 3 AFHS (OFF) 4 Ca 1dp 8 All 4 Printer (OFF)

  • Page 20: The Test Hardware Menu

    The setup & service menu The Test Hardware menu This can be used to identify a failed LED, check Fan and Gas Solenoid supply status and check the operation of the U Tube Sensor 1>Config 5 Maint 2 Interfaces Cycles through 01 to 11 as status and Changes from 0 to 1 with each 3 Ions warning LED’s are illuminated.
  • Page 21 The setup & service menu The voltages and temperatures will vary from those shown Selecting 4>OTA Raw shows the following screen above, however the 5v supply should remain within ±0.25v of nominal and the 12 and 24v supplies should remain within +/- 367 Raw 0.5v of nominal.
  • Page 22 The setup & service menu If a Service Key has been entered, a fifth option is displayed. Relay Test 1>LED etc 5 Relays 2 V+T Compressor 3 KeyMatrix 4 OTA Raw Gas FB = OFF The Gas Solenoid remains de-energised, the igniter stops Selecting 5>Relays initiates a test cycle showing the functioning and the Compressor runs for a few seconds following screens in sequence...

  • Page 23: The Maintenance Menu

    It can be used as a reminder of when to perform maintenance. Also shown are the instrument serial number and the main firmware version, hardware version and OTA firmware. (This information will be required if contacting your local agent or BWB).
  • Page 24 This enables the temperature to which the unit is controlled to incorrect code is made. be changed. The majority of BWB Flame Photometers will Precautions should be taken to avoid non-authorised personnel leave the factory with the Fan option set to 32. This is to...

  • Page 25: Flame Optimisation

    Flame optimisation Flame optimisation Aspiration Aspirate deionised water through the aspiration tube connected to After the initial 2 minutes of start-up, once the internal pump has the nebuliser. The tube should be fully immersed in the solution turned to operating speed; while viewing the flame through the and aspirated continuously at all times, other than when standards inspection port, slowly adjust the gas flow with the Fuel- and samples are being measured.

  • Page 26: Chart Recorder Configuration

    Chart recorder configuration Chart recorder / 4-20mA output (In this example Li is shown as having a valid single point calibration, A chart recorder may be connected to the instrument via the rear Ca as having a multi-point calibration). panel 4mm analogue output sockets (red and black). Select the ion which is to be monitored by the Chart Recorder.

  • Page 27: Firmware Updates (Reflashing)

    Firmware updates (re-flashing) BWB operate a policy of continuous development. It may occasionally be appropriate to update the firmware of a product to enable performance enhancements and provide the user with additional features and benefits. To facilitate re-flashing the product must be connected to a PC via the USB cable provided.
  • Page 28 An interruption can leave the instrument ceasing to function and will require a motherboard re-flash (normally conducted at BWB manufacturing facility or selected approved partners). When the re-flash download is complete a confirmation message will be displayed. Click OK to continue. The FP-PC software will now revert to the Welcome screen.
  • Page 29 Firmware updates (re-flashing) The Flame Photometer display will show the Welcome menu. If either The Hours reading or the Serial No. are incorrect, it Select Option 3>Setup will be necessary to enter the Service Key to reset these parameters. 1>Turn on Flame 2 Maintenance Navigate to the Config Menu and select Option 2>Reset 3 Setup...

  • Page 30: Recommended Tool Kit

    Recommended Tool kit For routine maintenance, service and engineer access the following BWB Fasteners Kit tools are required: Order yours today (Part number: FSTN-KIT) to ensure you’re • Suitable PPE – this may include gloves or mask depending on the never without a screw or critical component.

  • Page 31: Maintenance

    Monthly or 200 hours: • Carry out weekly maintenance procedures. BWB now offers an Annual Service Kit, containing all the parts you • Check the air (if using external air sources) and fuel gas need to keep your Flame Photometer running at peak performance.
  • Page 32 Maintenance 1. Unplug the mains power cord. 2. Remove the U-tube and waste tube, taking care not to spill Level Sensor – used to water. ensure there is adequate 3. Undo the thumbscrew and carefully drop the drain cup from the fluid in the U-tube.
  • Page 33 Maintenance No attempt should be made to remove (or adjust) the Aspiration Needle from the nebuliser body. Prior to carrying out this procedure ensure the flame is extinguished. Aspiration Needle and Aspiration Tubing Checking the Nebuliser: The heart of nebuliser function, the Aspiration Needle, should be 1.
  • Page 34 This should remove any stubborn deposits. 5. Soak the Nebuliser in a good detergent solution such as the BWB cleaning agent. 6. When fully clean, rinse the Nebuliser thoroughly with deionised water.
  • Page 35 Maintenance Mixing Chamber Cleaning The Burner must be completely cool before proceeding further. 12. Refit the Quad ring into the groove on the lower half of the mixing chamber. 1. Remove the Nebuliser from Mixing Chamber. 13. Inspect the gauze for any signs of deterioration and replace if 2.
  • Page 36 Maintenance Burner Cleaning The Burner must be completely cool before proceeding further. The Burner Assembly should be cleaned according to the maintenance schedule; or more frequently if the signal becomes erratic when aspirating deionised water. 1. Remove the Mixing Chamber as previously described. 2.
  • Page 37 Maintenance Inner Chimney/Ignition Electrode cleaning The Chimney Assembly and Burner must be completely cool before proceeding further. The Inner Chimney and Igniter should be cleaned according to the maintenance schedule; or more frequently if ignition is unreliable or the signal becomes erratic.
  • Page 38 Maintenance 7. Remove the Inner Chimney Windows from the Inner Chimney by removing the screws from the window retainers. 8. Clean the glass windows and chimney pieces using a non-abrasive cleaner or mild detergent solution, taking care not to scratch any of the surfaces.

  • Page 39: Electrical Schematic

    Electrical Schematic *indicates optional items based on model/ purchase configuration. Note: Ribbon cables are excluded from this diagram.

  • Page 40: Wiring Schematic

    Wiring Schematic...

  • Page 41: Motherboard Schematic

    Motherboard Schematic...

  • Page 42: Marshalling Board Schematic

    Marshalling Board Schematic...

  • Page 43: Air Flow Schematic

    Air Flow Schematic...

  • Page 44: Gas Flow Schematic

    Gas Flow Schematic...

  • Page 45: Gaining Access To The Instrument Enclosure

    Gaining access to the instrument enclosure To perform the following component or sub-assembly Some units have a printer unit fitted to this cover. In such cases replacement or servicing procedures it will first be necessary to care should be taken that the printer and its connection cables are access the interior of the instrument enclosure.
  • Page 46 Gaining access to the instrument enclosure 4. Remove the four screws holding the Front 5. Place bubble wrap or a soft material on the table in front of the Panel Assembly in place front panel to protect the keypad. Carefully lower the Front Panel Assembly down on the table being aware that it is retained to the instrument by cables at the bottom.

  • Page 47: Component Overview

    Instrument main chassis, component overview Optical Train Assembly (OTA) Optical Train Ribbon Cable Cooling Fan Gas Solenoid Valve Marshalling PCB Air filter, partial replacement connection Air Compressor (refer to air filter replacement) Compressor Air Filter Control PCB Air inlet filter Gas Flow Control Valve Gas Filter...

  • Page 48: Instrument Front Panel

    Instrument front panel, component overview LCD Ribbon Cable Motherboard Optical Train (OTA) Ribbon Cable Primary Ribbon Cable Keypad Ribbon...

  • Page 49: Replacing Components

    Replacing the OTA Gain access to the instrument enclosure as previously described. 2. Remove internal fixing screw using a 7mmAF spanner or nut spinner. 3. Remove the screw in the rear panel fixing using a T20 Torx driver. 4. Remove the Optical Train Assembly, taking care not to touch the optical face. 5.

  • Page 50: The Chassis Fan

    Replacing the Chassis Fan 1. Gain access to the instrument enclosure as previously described. 2. Identify the fan electrical connection on the Marshalling PCB. Carefully unplug the connector by pulling upwards 3. Remove the 2 x 5.5mmAF nuts which secure the cooling fan to the rear panel and withdraw the fan 4.

  • Page 51: The Gas Solenoid

    It is essential that a leakage check is performed using a soap solution or a BWB leak detection solution once the unit is put back to functional condition, but before replacing the Front Panel and Top Cover securing screws. Initiate a flame start sequence allowing the solenoid to pass gas, lower the Front Panel and check all gas connections for leaks whilst flame is alight.

  • Page 52: The Air Compressor

    Replacing the Air Compressor Gain access to the instrument enclosure as previously described. 2. Disconnect the power to the pump and remove the earth cable 3. Disconnect the pump fan from the Marshalling PCB. 4. Cut the cable tie and remove the air inlet air outlet tubes. 5.

  • Page 53: The Air Filter

    Replacing the Air Filter Access to the instrument enclosure and the outer chimney is required for a full replacement to take place. A partial replacement can be conducted without accessing the outer chimney by replacing the tube up to and including the blue connector piece on the inside of the main chassis.
  • Page 54 Replacing the Air Filter...

  • Page 55: The Air Inlet Filter

    Replacing the Air Inlet Filter Gain access to the instrument enclosure as previously described. 2. Locate the air inlet filter and remove the tube from the barbed fittings on the pump. 3. Replace the assembly and feed the suction tube through the P clip on the left hand chassis wall (this ensures air flow consistency is maintained).

  • Page 56: The Gas Filter

    It is essential that a leakage check is performed using a soap Gas Filter solution or BWB leak detection solution once the unit is put back to functional condition, but before replacing the Front Panel and Top Cover securing screws. Initiate a flame start sequence allowing the solenoid to pass gas, lower the Front Panel and check all gas connections for leaks whilst flame is alight.

  • Page 57: The Gas Fuel Adjustment Valve

    (2). It is essential that a leakage check is performed using a soap solution or BWB leak detection solution once the unit is put back to functional condition, but before replacing the Front Panel and Top Cover securing screws.

  • Page 58: The Gas Regulator

    It is essential that a leakage check is performed using a soap solution attempt to disassemble the gas regulator. or BWB leak detection solution once the unit is put back to functional condition, but before replacing the Front Panel and Top Cover Note: It is recommended that the OTA is removed before securing screws.

  • Page 59: The Keypad

    Replacing the Keypad Gain access to the instrument enclosure as previously described. 2. Identify and disconnect the keypad connector from the motherboard. 3. Carefully place the Front Panel Assembly back into position on the instrument. Using a knife blade or a thin flat screwdriver, carefully lift a corner of the membrane (2).

  • Page 60: The Marshalling Board (Pcb)

    Replacing the Marshalling Board (PCB) Gain access to the instrument enclosure as previously described. 2. Remove any USB or RS232 connections from the rear of the instrument. 3. Disconnect all connections from the marshalling board. 4. Remove the 4 retaining screws using a T10 torx driver. 5.

  • Page 61: The Motherboard (Pcb)

    Replacing the Motherboard (PCB) Gain access to the instrument enclosure as previously described. 2. Disconnect all connections from the Disconnect all connectors motherboard. 3. Remove the 4 retaining screws using a T20 torx driver. 4. Replace the motherboard. 5. Reassemble the instrument in reverse order.

  • Page 62: The Lcd/Lcd Ribbon

    Replacing the LCD / LCD ribbon Gain access to the instrument enclosure as previously described. 2. Disconnect the ribbon cable from the LCD and motherboard. 3. Remove the 4 retaining screws using a A/F 3.5mm spanner. 4. Replace the LCD and ribbon cable. 5.

  • Page 63: The Ignition Module

    Replacing the Ignition Module 1. Access the rear of the chimney by removing the 6 retaining screws using a T20 torx driver. 2. Unplug the chimney fan from the connection on the chassis side wall. Note the cable location (tucked down the side of the ignition module –...
  • Page 64 Replacing the Ignition Module Power cable connections Earth stud, cable and nut Please note, for clarity the bracket is shown with the chimney removed. It is not necessary to remove the chimney!

  • Page 65: The Chimney Fan

    Replacing the Chimney Fan 1. Access the rear of the chimney by removing the 6 retaining screws using a T20 torx driver. 2. Unplug the chimney fan from the connection on the chassis side wall. Note the cable location (tucked down the side of the igntion module – it is vital the cable is placed back in this position).

  • Page 66: The Ignitor

    Replacing the Igniter 1. Access the rear of the chimney by removing the 6 retaining screws using a T20 torx driver. 2. Unplug the chimney fan from the connection on the chassis side wall. Note the cable location (tucked down the side of the igntion module –...
  • Page 67 Replacing the Igniter...

  • Page 68: The Inner Chimney Windows

    Replacing the Inner Chimney Windows 1. Access the rear of the chimney by removing the 6 retaining screws using a T20 torx driver. 2. Unplug the chimney fan from the connection on the chassis side wall. Note the cable location (tucked down the side of the ignition module –...
  • Page 69 Replacing the Inner Chimney Windows...

  • Page 70: The Optic Windows

    Replacing the Optic Window Gain access to the instrument enclosure as previously described. 2. Remove the OTA assembly as previously described. 3. Remove the 4 optic window retaining nuts using a 7mm A/F spanner. 4. Replace the window (and gasket if required). 5.

  • Page 71: The Burner

    Replacing the Burner 1. Remove the mixing chamber by gently pulling back on the 2 release tabs and pulling the mixing chamber in a downwards direction. 2. Remove the 2 thumb screws holding the burner flange into position, whilst securely holding the burner (failure to hold the burner will cause it to drop out when the screws are removed).

  • Page 72: The Mixing Chamber

    Replacing the Mixing Chamber 1. Remove the nebuliser from the mixing chamber. 2. Disconnect the gas tube from the mixing chamber. 3. Remove the U-Tube from the base of the mixing chamber. 4. Remove the mixing chamber by gently pulling back on the 2 release tabs and pulling the mixing chamber in a downwards direction.

  • Page 73: The O-Rings

    Replacing the O-Rings (O-Ring Kit) An O-Ring kit is generic to all models and backwards versions. Not all O-Rings supplied may be required for your model or instrument version. 1. Remove the drain cup from the mounting bracket and use a 10 spanner to remove the outlet drain barb, replace the o-ring.

  • Page 74: The Motherboard Battery

    Replacing/ removing the Motherboard Battery The European Parliament and EU Council have set the goal of reducing the amount of Waste Electrical and Electronic Equipment (WEEE) going to landfill and reducing the hazardous substance content of Electronic and Electrical Equipment (EEE). Please follow the following steps to decommission your flame photometer prior to recycling Gain access to the instrument enclosure as previously...

  • Page 75: The Printer

    Replacing the Printer Gain access to the instrument enclosure as previously described. 2. Remove the earth cable from the printer housing. 3. Disconnect the power cable and ribbon cable from the printer. 4. Replace the printer enclosure with the new component. 5.

  • Page 76: Upgrading To 'Afhs Enabled

    Upgrading to ‘AFHS enabled’ Gain access to the instrument enclosure as previously described. 2. Remove the blanking grommet from the rear of the instrument by pushing it out from the inside. 3. Insert the AFHS Reservoir Low Level socket assembly as provided in the kit of parts.

  • Page 77: Upgrading (Installing) The Printer Module

    Upgrading (installing) the Printer Module Gain access to the instrument enclosure as previously described. 2. Remove the earth cable from the top panel cover. 3. Plug the Printer Interface PCB into the socket on the marshalling board and secure it in place using the 2 supplied screws in the holes as identified in the image.

  • Page 78: Upgrading To Ma Output Functionality

    Upgrading to mA Output functionality Gain access to the instrument enclosure as previously described. 2. Locate the ‘jumper link’ on the motherboard and re-position it to the 2 alternate pins. 3. Fit the mA interface PCB using the supplied screws and fasten using a T10 torx driver.
  • Page 79 Use this space for your own notes...
  • Page 80 Use this space for your own notes...

  • Page 81: Annex A

    Important Note: This document is a general risk assessment for the use of BWB Flame Photometer Range. This risk assessment should be reviewed fully by users of the instrument prior to use for the first time and in the event that it is not sufficient to control the risk posed by the model in question then the user should include additional risk control measures and more specific information on the particular application, it is the responsibility of the organisation to ensure the risks identified by BWB and/or your own assessment are mitigated and employees or operators of the system are sufficiently protected from harm.
  • Page 82 Residual Risk Significant Hazard Perceived Nature of Risk Control Measures Low (L) / Medium (M) / High (H) Flammable / Explosive Substances Gas (propane, butane, natural Local exhaust ventilation covering the region where gas)leak leading to explosion equipment is to be used. Upon initial connection of gas tube and propane tank, joints are to be checked with a “digital gas sniffer”, leak detection spray or other suitable test.
  • Page 83 Residual Risk Significant Hazard Perceived Nature of Risk Control Measures Low (L) / Medium (M) / High (H) Chemical Storage Flammable organic liquids in Flammable materials/ fluids should be stored away from vicinity of flame photometer. the flame photometer at all times, ideally in protective cabinets.
  • Page 84 Residual Risk Significant Hazard Perceived Nature of Risk Control Measures Low (L) / Medium (M) / High (H) Electrical Safety Power to instrument Carry out regular PAT testing according to company’s PAT testing routine and process. Only approved persons, the manufacturer or appointed distributors are to carry out electrical work inside the instrument.

  • Page 85: Annex B

    [ ]Blood [ ]Acids the instruments return. Please contact BWB on +44 (0) 1787 274 (or products of) (corrosive and non-corrosive) 870 or speak to your local distributor should you require any advice [ ]Urine (or other human liquids) in completing this form.

  • Page 86: Annex C

    Annex C Navigation menu flow diagram...

  • Page 87: Annex D

    Annex D LCD error messages *** ERROR *** *** ERROR *** * Pre-Flame level * * U-Tube Fault * Resetting instrument Resetting instrument *** ERROR *** * Flame gone out* Indicates too much ‘stray’ light is Indicates that the drain cup switch entering the device, the sensors has not detected a suitable level of Resetting instrument...
  • Page 88 14. If the above steps have failed to overcome the false alarm requested from BWB. the steps can be repeated to increase the level or alarm to the In order to disconnect the sensor please follow the instructions maximum value of 0.9.
  • Page 89 Annex D LCD error messages Bad Correct-Cal Reqd *** ERROR *** * Flame gone out* Warm-up in XX min Low air pressure Indicates that the instrument flame Indicates that the calibration Indicates that the air pressure has not been on for a sufficient correction just performed was not detected by the instrument is not time to reach optimum warm up.
  • Page 90 Annex D LCD error messages *** ERROR *** ** Service Mode Reqd ** * HIGH CHIMNEY TEMP* Wrong Soln! ACCEPT? Resetting instrument Indicates that service mode is Suggests that the instrument Indicates the internal chimney is required to perform the intended believes the wrong solution has above the limits for temperature functionality.
  • Page 91 The information contained in this document was correct at the time of publishing. However, BWB Technologies Ltd reserves the right to change specifications, equipment, and procedures at any time, without notice. To obtain a current version contact your local agent or go to http://www.bwbtech.com/...

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