™

Kjeltec 1002 System

Distilling Unit
User Manual
1000 1535 / Rev. 2.3

1002001A

Copyright 2003 / All rights reserved

FOSS Tecator AB, Box 70, SE-26321 Höganäs, Sweden
Tel Int +46 42 361500, Fax +46 42 343150
 Dansk
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1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

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1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden
 Table of Contents

1 SAFETY PRECAUTIONS AND PROCEDURES

1.1 Intended Use .............................................................................................1
1.2 Safety Precautions .................................................................................1
2 INTRODUCTION
2.1 Performance Data ..................................................................................3
3 FUNCTION
3.1 Principle of Operation .........................................................................4
3.2 Steam Generation ..................................................................................5
3.3 Alkali System ............................................................................................5
4 PREPARATIONS FOR USE
4.1 Unpacking and Checking....................................................................6
4.2 Installation .................................................................................................7
4.2.1 Installation Requirements ...........................................................................7
4.2.2 Fuses .................................................................................................................7
4.2.3 Installation Instructions................................................................................7
4.3 Functional Verification .......................................................................8
4.3.1 Testing Recovery............................................................................................8
5 OPERATION
5.1 Identification of Controls ..................................................................9
5.2 Starting Up .................................................................................................9
5.3 Distillation ..................................................................................................9
5.4 Closing Down ..........................................................................................10
6 MAINTENANCE
6.1 Daily..............................................................................................................11
6.1.1 Cleaning Cycle ..............................................................................................11
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

6.1.2 Cleaning of Unit ..........................................................................................11

6.1.3 Rubber Adapter ...........................................................................................11
6.2 Weekly .......................................................................................................11
6.2.1 Reagent Tanks Inspection and Cleaning................................................11
6.2.2 Digestion Tubes Inspection .......................................................................11
6.2.3 Cleaning the Safety Door ..........................................................................12
6.3 Every One to Three Months............................................................12
6.3.1 Controlling the Rubber Adapter..............................................................12
6.3.2 Controlling the Alkali Volume .................................................................12
6.3.3 Cleaning the Alkali Pump..........................................................................13
6.3.4 Cleaning of the Splash Head ....................................................................13
6.3.5 Depending on Number of Analyses ........................................................13
6.3.6 Cleaning of the Steam Generator ...........................................................14
6.3.7 Every Year .....................................................................................................14
7 TROUBLE SHOOTING
8 FOSS Tecator AB APPLICATION NOTES SYSTEM
9 TECHNICAL SPECIFICATIONS
9.1 Safety...........................................................................................................18
9.2 Environmental Conditions ..............................................................18
9.3 Storage and Transport ......................................................................19
9.3.1 Lifting Instructions 1002 ............................................................................19
10 ACCESSORIES AND SPARE PARTS
10.1 Accessories ...............................................................................................20
10.2 Spare Parts................................................................................................20
10.3 Kjeltabs .......................................................................................................20
10.4 Manufacturer’s Name and Address .........................................21
11 SAFETY PRECAUTIONS AND PROCEDURES ..........23
12 SICHERHEITS- UND BETRIEBSVORSCHRIFTEN (DE)
26
13 SIKKERHED - FORHOLDSREGLER OG PROCEDURER
(DK) .............................................................................................................30
14 PRECAUCIONES Y PROCEDIMIENTOS DE
SEGURIDAD (ES) ..............................................................................33
15 VAROTOIMET JA MENETELMÄT (FIN) ..........................37
16 PRESCRIPTIONS ET PROCEDURES DE SECURITE (FR)
40
17 ËÇØÇ ÌÅÔÑÙÍ ÁÓÖÁËÅÉÁÓ ÊÁÉ ÏÄÇÃÉÅÓ ×ÑÇÓÇÓ
(GR) ..............................................................................................................44
18 ÖRYGGISREGLUR OG AÐFERÐIR (IS) .........................48
19 NORME PRECAUZIONALI E PROCEDURE DI
SICUREZZA (IT) ...............................................................................51
20 VEILIGHEIDSMAATREGELEN EN PROCEDURES
(NL) ..............................................................................................................55
21 SIKKERHETSREGLER OG PROSEDYRER (NO) ......59
22 PRECAUÇÕES E MEDIDAS DE SEGURANÇA
(PT) ..............................................................................................................62
23 SÄKERHETSFÖRESKRIFTER OCH 1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden
TILLVÄGAGÅNGSSÄTT (SE) ...............................................66
The Kjeltec Auto 1002 Analyzer is designed
for laboratory use analyzing parameters as
specified in FOSS Tecators Application Notes.

The responsible body shall be made aware

that, if the equipment is used in a manner not
specified by the manufacturer, the protection
provided by the equipment may be impaired.

Please read these operating instructions

carefully and act accordingly.

For safety reasons people not familiar with

these operating instructions must not use the
instrument.

In order to find out the nature of the

potential hazard, please consult this manual
in all cases where this symbol is used.

Careful handling of the solutions used in an

analysis is mandatory for laboratory safety.
Refer to the appropriate material safety data
sheet for reagent handling instructions.
Eye protection should be worn at all times
and care should be taken when handling hot
digestion tubes.

This device is equipped with a

grounding/earthing type power plug for your
protection against electrical shock hazard
and should only be attached to a properly
grounded/earthed receptacle.

Before replacing the fuses, disconnect

incoming mains supply.

Covers or panel(s) should be removed by

qualified personnel only.
Terminals identified by the symbol, bring the
various parts of a system to the same
potential e.g. ground potential, when
connected together. Note that such a terminal
must not be used as a protective earth
(ground) connection.

Modifications, alterations, rebuilding or use

of safety parts not authorized by FOSS
Tecator AB violates the warranty. FOSS
Tecator AB has no responsibility for damages,
material or personal, occuring as a result of
such actions.
 2 INTRODUCTION

The 1002 Distilling Unit is part of the Kjeltec System I. Together

with the 2006 Digestion System and a Titration Unit, official
determinations of nitrogen / protein according to the Kjeldahl
method, can be performed.

The 1002 Distilling Unit is a convenient and safe instrument for

rapid steam distillations. One of the main applications for the unit
is the distillation of “Kjeldahl digests” where the alkali is
conveniently added via a built in dispensing system. The distillate
is collected in a Receiver flask for subsequent titration.

Many other distillations can be performed efficiently with the

1002 Distilling unit. These include Sulphur dioxide, Cyanide,
Phenol, Alkaline Direct Distillation and Alcohol. Ask your FOSS
Tecator AB representative for a copy of our extensive application
list.

2.1 Performance Data

Distilling time 4-5 min

Distillation capacity Approximately 10 samples per
hour
Measuring range 1-160 mg
Reproducibility ± 1 % relative
Recovery 99,5-100,5 %
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

1002003A

Fig. 1 A complete Kjeldahl system.

3
 3 FUNCTION
3.1 Principle of Operation
A typical Kjeldahl distillation is described. Other reagents might
be used in other analyses. Use figure 2 to identify the parts. A test
tube (Pos. 2) with digested sample, diluted with 75 ml distilled or
deionised water, is connected to the splash head (Pos. 3). Alkali is
pumped (Pos. 1) into the test tube when the alkali handle on the
front panel is pulled down. The distillation is started by opening
the steam valve (Pos 7), pushing the steam control handle on the
front panel, marked STEAM, in the OPEN (down) position. The
liberated Ammonia goes, together with steam, through the splash
head (Pos.3) and is cooled in the condenser (Pos. 10) and
collected in the receiver flask (Pos. 11).

12

3
13

10
7

11
5
1

1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden
4 6

9 ALKALI
TANK
8

WASTE
COOLING WATER STEAMGEN 1002014A
INLET DRAIN
VALID FROM SERIAL NO 5400
Fig. 2 1. Alkali pump 2. Test tube 3. Splash head 4. Steam generator 5. Level pins 6. Over heat protector 7. Steam valve
8. Double valve for cooling water and water for steam production 9. Drain valve (steam generator)

4
 3.2 Steam Generation
By opening the steam valve on the front panel, power is connected
to the heater in the steam generator (Pos.4), the cooling water
inlet valve opens, and the distillation starts. The steam generator
must contain a certain volume of water to operate. The correct
water level in the steam generator is automatically controlled by
level pins (Pos. 5).

When the steam valve is closed, boiling continues for about 10

seconds in the steam generator. The excess steam goes to drain via
the waste tubing. At the same time the cooling water is switched
off automatically. No overpressure can develop. The generator is
either connected to the test tube or to drain. In addition there is a
safety valve on the steam generator if for any reason the steam
outlet is blocked.

3.3 Alkali System

Make sure that the test tube is empty and in its proper position.
Pull down the handle for dispensing alkali (Fig. 8) several times,
until alkali flows into the test tube. Then press the handle rapidly
all the way down 3 - 4 times to remove all the air from the system.
Always let the handle return to its upper position by itself. One
stroke will give approximately 50 ml of alkali. See the
maintenance section, how to change the volume.

In some applications other reagents may be added using

the alkali system. e.g. H2SO4, H3PO4.

Note: The flowscheme shows a system using tap water feed

for the steam generator. The water supply should be
ammonia free to keep blank values at a minimum. If distilled
or deionised water is used a direct feed water system must
be fitted. (Contact your FOSS Tecator AB representative).
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

5
 4 PREPARATIONS FOR USE
4.1 Unpacking and Checking
Unpack the 1002 Distilling Unit and its accessories with care.
Remove all packing material.

Remove the plastic caps covering the outlets on the rear of the
instrument. Use a pair of pliers if necessary.

Use the parts list, packed together with the instrument and check
that you have received all parts. Use Fig. 3 and 4 to identify the
different parts. If any parts are missing, contact your FOSS
Tecator AB representative.

2
1
4

6 5 9 7 3

1002004A

Fig. 3 1. Distilling unit 2. Alkali tank 3. PVC Tubing for drain 4. Handle 5. Tubing clamps for water tubing 6. Tubing
clamps for alkali tubing 7. Reinforced PVC Tubing for alkali 8. Nipple 9. Reinforced tubing for water(with integral
connectors)

7 5 1
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

6
3
4
1002005A

Fig. 4 1. Manual 2. Dispensing stops 3. Rubber adapter, semi-micro 4. Rubber adapter, macro 5. Digestion tube 250 ml
6. Reciever flask (set of 8) 7. Funnel

6
 4.2 Installation
4.2.1 Installation Requirements
3 4 5 6 7
Power supply 220-240 V, 50-60 Hz

1 2 Power consumption 1900 W

Water supply 1 l/min tap water at 20° C
Water pressure (max) 5 bar
Dimensions LxDxH 30x36x80 cm
Weight 25 kg
1002006A

Fig. 5 Connections left to right.

1. Steam waste tubing 2. Cooling water 4.2.2 Fuses
inlet 3. Steam generator drain 4. Water tank
(for direct feed water systems only) External: One fuse T 10 A
5. Alkali inlet 6. Electric power cable
7. Equipotential connector
Internal: One fuse F 125 mA and
one fuse T 500 mA

4.2.3 Installation Instructions

Place the 1002 Distilling Unit close to a cold
water tap and appropriate power supply which
should be grounded.
The connections are: brown wire-line, blue
wire-neutral and green/yellow-protective
earth.

a)Place the alkali tank on the floor beside

the distilling unit.

b)Direct the waste tubing into the sink. Make

sure that the outlet is not below the water
level in the sink.

c)Connect the alkali tubing from the alkali

1002006B
tank to the nipple labelled “ALKALI”
(Fig.5). Secure with tubing clamps (Fig.6).
Fig. 6 Use tubing clamps to secure
Fill the alkali tank with sodium hydroxide
tubings. prepared as described in the Application
Note AN 300.
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

d)Screw the black plastic nipple supplied

into the DRAIN outlet, put a piece of tubing
on the nipple and direct it into the sink.

e)Connect the reinforced tubing with integral

connectors to the cooling water inlet (
Fig.7) and to the water tap using thread
sealing tape if necessary. If you do not
have a threaded tap, cut the metal connector
off one end of the tubing and secure the
1002006C
tubing to the tap with the tubing clamp
provided.
Fig. 7 Water connection.
f)Connect the distilling unit to the power
supply.

7
g)Do the start up procedure according to 5.2
and check that the temperature of the
condensate is below 25 - 30°C. If not,
increase the flow of the cooling water
stepwise.
Mark the cooling water tap in order to give
the same flow at all times.

4.3 Functional Verification

4.3.1 Testing Recovery
Please refer to Application Note 300 supplied
with your system, section chemical check.

1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

8
 5 OPERATION
1 2 3 4
5.1 Identification of Controls
These are identified in Figure 8.
1. Power switch
2. Timer
3. Steam control
UP CLOSED
DOWN OPEN
5 4. Alkali handle
5. Safety door
1002007A
5.2 Starting Up
Fig. 8 1. Power switch; 2. Timer;
3. Steam control; 4. Alkali handle; 5. Safety a)Check the level of alkali in the tank. Fill
door. up if necessary.

b)Make sure that a test tube and a receiver

flask are placed in their proper positions
and that the safety door is closed.

c)Switch on the power.

d)Turn on the cold water tap

Note: The water for the condenser and steam generator will
not flow until the steam valve is in the open position with
the power on. It will stop automatically when the valve is
closed.

e)Open the valve for steam by pushing the

1002007B steam control handle on the front panel in
down position (Fig. 9).
Fig. 9
After a couple of minutes steam is
generated. Let the distillation continue
until some water is collected in the
receiver flask. The system is then heated
up.
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

g)If the platform with the receiver flask is

in the upper position (Fig. 10), move it to
the lower position. Close the steam valve on
the front panel.

5.3 Distillation
a)Remove the test tube and the receiver flask.

1002007C
b)Place the tube with the first diluted Sample
to be distilled in its position and place
Fig. 10 the receiver flask with the receiver
solution on the platform. To avoid
contamination don’t touch the glass outlet
tube with your fingers. Hold it by its
plastic tubing if necessary.

9
c)Close the safety door.

d)Move the platform for the receiver flask to

its upper position.

e)Gently pull the alkali handle all the way

down to dispense about 50 ml of alkali (Fig
8).

f)Open the steam control and set the timer to

the appropriate distilling time (around 4
minutes).

g)Lower the platform for the receiver flask

and continue distillation for a few more
seconds to rinse the outlet tip.
1002008A
Close the steam control.
Fig. 11 Resting position for the teflon
h)Replace the test tube and the receiver flask tube
with the next set and continue in the same
manner with all the samples. When removing a
tube, the teflon pipe through which the
steam enters the sample, should be placed in
the slot of the plastic holder (Fig. 11).
This makes it possible to replace a tube
without touching the teflon pipe which will
have traces of alkali on it.

5.4 Closing Down

a)Do the daily maintenance according to
chapter 6.

b)Pull out the drain collector (Fig. 12) under

the tube holder and the platform for the 1002013A
receiver flask and clean it with water.
Wipe the instrument clean from any Fig. 12
spillage.

c)Switch off the power and close the water

tap.
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

10
 6 MAINTENANCE
This text is also avaliable as an instruction 10006458 which
includes Maintenance Record Charts to facilitate a record of your
actions.

6.1 Daily
To avoid start up problems and to prolong the
lifetime of your system the procedures
described in this chapter should be performed
every day the unit is used.

6.1.1 Cleaning Cycle

Connect a test tube half filled with distilled
water and a receiver flask into their
positions. Open the valve for steam and distil
for 3 minutes, in order to avoid chemical
residues to remain in the lower part of the
splash head.

6.1.2 Cleaning of Unit

Clean the whole unit from any spillage with a
damp cloth or sponge.

6.1.3 Rubber Adapter

Clean the adapter from all remaining residues
with a damp cloth or sponge, use warm water.
Also clean the splash shield from residues.

6.2 Weekly
In addition to the daily routines outlined
above, the following procedures should be
performed on a weekly basis, or as the need
arises. Use the Weekly Maintenance Record
Chart provided to keep a record of these
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

operations.

6.2.1 Reagent Tanks Inspection and Cleaning

Check the tanks for: Signs of cracks or
splitting. Replace the tank if damaged.
Crystals blocking the air holes in the screw
cap. To remove any crystals wash the screw cap
in clean warm water until the crystals are
dissolved, dry and replace.

6.2.2 Digestion Tubes Inspection

Check the rims of the digestion tubes for
uneven surface,cracks and chips. This type of
damage can cause leakage between the tube and
the rubber adapter leading to loss of recovery
during analysis. Look for scratches and star
fractures on the base of the tubes. These can
lead to untimely and unexpected breakages

11
creating a safety hazard to you and your
colleagues and potential damage to your
digestion or distillation unit.

Discard all damaged tubes in the interest of

safety.

After some digestions the base of the tubes

may take on an off-white to greyish
coloration. This is quite normal and does not
require the tubes to be replaced.

6.2.3 Cleaning the Safety Door

Clean the safety door from any spillage with
a damp cloth or sponge.

6.3 Every One to Three Months

In addition to the routines outlined above the
following procedures should be performed
every one to three months, or as the need
arises, depending on usage. Use the
Maintenance Record Chart provided with the
instruction to keep a record of these
operations.
Important!
If the rear panel is removed, there is a grounding cable
(yellow/green) connected inside between the rear panel and
the main cabinet (lower right corner). Be sure to reconnect
when replacing the panel.

6.3.1 Controlling the Rubber Adapter

Remove the rubber adapter from the unit and
inspect it for scratches and cracks. Note also
if the rubber of the adapter has started to
lose it softness. If the adapter show signs of
scratches, cracks or that the rubber has
started to lose its softness the adapter has
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden
to be changed.

6.3.2 Controlling the Alkali Volume

· Connect an empty test tube to the unit.

Mark the wanted volume with a pen on the
tube. Alternatively, the content can be
poured in a measuring cylinder.
· Close the safety door.
· Switch on power.
· Gently pull the handle all the way down to
dispense the alkali.
· Check the volume a couple of times. The
amount of alkali is set to about 50 ml from
the factory. This volume can be reduced by
Fig. 13

12
 putting dispensing stops in the slot below
the alkali dispensing handle. Turn them 90°
to fix them in position fig.13.

· After any adjustment, check the volume

again.

6.3.3 Cleaning the Alkali Pump.

Put approximately two litres of warm, 40°C,
distilled water in a beaker and connect it to
the system.Pump about half a litre of the
water through the alkali pump by pressing the
alkali handle. This procedure requires that
the tube is emptied when about 200 ml has been
dispensed. Replace the tube and continue the
flushing.

6.3.4 Cleaning of the Splash Head

Pour about 25 ml of water and the same amount
of concentrated acetic acid into a test tube
and distil for 5 to 10 minutes. Replace the
tube with a clean tube and continue to distil
for another 5 minutes. Repeat this at least
three times so no acid residues will interfere
with the analysis.

6.3.5 Depending on Number of Analyses

The frequency with which you should carry out
the procedures in this chapter depends upon a
number of factors which are outside FOSS
Tecator AB’s control and are therefore
difficult to predict. In simple terms you will
have to judge the required frequency by
physically checking the situation in each
case. To a large extent the frequency will
depend on two major points.

1.The quality of the water used for steam

generation. For example tap water will
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

create more or less salt deposits depending

on its hardness. If deionised water is
used,cleaning will rarely be necessary, but
please remember that a certain level of
conductivity is required for correct
operation of the level pins (See trouble
shooting)

2.How well you have followed the guidelines in

the first three chapters of this text.
Regular and immediate cleaning of splashes
and spillage will create less problems.
Routine checking of connectors when the
reagents are replaced will limit the
likelihood of leakages.

13
6.3.6 Cleaning of the Steam Generator
Disconnect the power supply. Open the drain
valve for the generator. When empty, fill up
the generator with a solution of 100 g citric
acid in 800 ml water, preferable hot, by
connecting the funnel to the steam generator
drain. Suspend the funnel so that is in higher
position than the steam generator. Close the
drain valve, whilst the funnel is still
suspended above the steam generator.

Alternative 1.Leave the solution in the steam

generator overnight, or until the generator
vessel is free from deposits.

Alternative 2.Connect the power supply. Place

a distillation tube and a receiver flask in
their positions and close the safety door.
Switch on power and open the steam valve. Let
the citric acid solution boil for about five
minutes. Close the steam valve and disconnect
the power supply.

Caution
If Alternative 2 has been chosen the solution will be
extremely hot!

Open the drain valve and empty the steam

generator.
Rinse the generator thoroughly with water
using the funnel again. When the vessel is
clean and rinsed, close the drain valve.
Remove the funnel and put the drain tubing
outlet back to its normal position.

6.3.7 Every Year

Your local distributor offers Service
Agreements in order to make your instrument
reliable in performance and safety.
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden
As a minimum of care all tubings and
connectors should be inspected. Exchange if
visible damages can be seen.

14
 7 TROUBLE SHOOTING

FAULT PROBABLE CORRECTIVE

CAUSE MEASURE
A. Lamp in main No current to the Check power supply.
switch does not lit unit.
up. Call service.
Faulty lamp and/or
switch.
B. Alkali is not Alkali tank is empty. Fill up the tank.
dispensed.
Crystals on sealing Read Maintenace
valves. section Clean Alkali
pump.
C. No cooling water. No cooling water on. Turn on the water
tap.
Sieve in the cooling
water inlet clogged. Rinse the sieve.

Double valve faulty.

Call service.
No water in the
steam generator. See below.
D. No water in the No cooling water on. Turn on the water
steam generator. tap.
Sieve in the cooling
1002018A water inlet clogged. Rinse the sieve.

Fig. 14 To reset the overheat protector Double valve faulty.

insert a screwdriver in the hole and press Call service.
until you hear a clicking sound
E. No steam is Not enough water in Check that the drain
generated. the steam valve is closed.
generator. Check level pin
position.

Steam valve faulty if Call service.

steam comes trough
the waste tubing,
when steam is on.

No current to Check the overheat

heater. protector. Reset if
neccessary according
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

to fig 14. If this is

not solving the
problem call service.
F. Steam generator Non return valve for Call service.
is overfilling. steam or drain
faulty.
(Direct Feed Water Add 0,5 g Na 2 SO 4 to
Systems only.) No conductivity in water tank. Do not
the water use Borax or Sodium
preventing Sulphate as this may
activation of level cause foaming.
pins if distilled
water is used.
G. Temperature of Too low water flow Adjust water flow or
the distillate above through condenser, use water supplied
30°C or too high water via a chilling unit.
temperature.

15
 FAULT PROBABLE CORRECTIVE
CAUSE MEASURE
H. Incorrect Sample preparation Check weighing and
analytical results ( the whole digestion
too high or too low) procedure.

Titrant Standarise titrant.

concentration Check distillation &
titration cycle by
distilling known
amounts of
ammonium salts. See
testing recovery.

Check tubings and

Leakage. the rubber adapter.
Test recovery.

Read maintenance
Alkali volume too section.
low.
See G above.

Distillate
temperature too Use distilled or
high. deionized water.*

Water for steam

production contains
excessive or variable
amounts of
ammonia.
I. Other undefined Chemistry/applicatio Contact your FOSS
or unspecified n. Over 95% of Tecator AB
problems problems are related representative.
to the chemistry of
customers specific
applications.

Systems Contact your FOSS

malfunctions not Tecator AB
mentioned above. representative.

* This requires the fitting of a direct Feed Water System and must
be carried out at the factory or by a certified FOSS Tecator AB
service engineer in your laboratory.
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

16
 8 FOSS Tecator AB
APPLICATION NOTES
SYSTEM

For information about preparation of chemicals and the Kjeldahl

method please see the Application Note AN 300 supplied with
your system.

In FOSS Tecator ABs extensive list of Application Sub Notes you

will find information on how to analyse the sample of your
choice. Please contact your FOSS Tecator AB representative for
more details.
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

17
 9 TECHNICAL
SPECIFICATIONS
9.1 Safety
The insulation of external, inaccessible
circuits is reinforced.

9.2 Environmental Conditions

The equipment is designed to be safe at least
under the following conditions:

1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

Fig. 15

18
 · Indoor use
· Altitude up to 2000 m.
· Temperature 5°C to 40°C.
· Maximum relative humidity 80% for
temperatures up to 31°C decreasing linearly
to 50% relative humidity at 40°C.
· Mains supply voltage fluctuations not
exeeding ± 10% of the rated voltage.
· Transient overvoltage is according to
category II, which is normal for this type
of equipment.
· Pollution degree 2

9.3 Storage and Transport

9.3.1 Lifting Instructions 1002
This instrument is not equipped with handles
or grips. Two persons are needed to lift the
instrument, following the instructions below:

1. Tilt the instrument slightly backwards,

and lift and support the instrument as
shown in fig.16 to simplify and ensure a
safe lift.

2. Weight 25 kg.

Caution
Avoid getting your fingers pinched!

1002017A
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

Fig. 16

19
 10 ACCESSORIES AND
SPARE PARTS
10.1 Accessories
1000 0164 Receiver Flasks, 250 ml (set of 8)
1000 0427 Basket for handling of 12 receiver flasks
1002-020 Titration Unit, complete, DIGITRATE 50 ml
capacity
1000 0347 Kjeltec DD KIT Comprising:
2ea 1000-0787 Distilling Tubes 750 1 (set of 6)
1ea 1000-2049 Stand for 12 DD tubes
2ea 1000-0439 Receiver flasks set of 6
1ea 1000-0427 Basket for 12 Flask
1ea Application Note

10.2 Spare Parts

1000 0299 Condenser with insulation
1000 0725 Splash Head, complete
1000 0056 Adapter for test tubes 250 ml
1000 0487 Adapter for test tubes 100 ml
1000 0593 Alkali Tank
1582 0002 Tubing for steam ¢ 8/12 m m, per m
1582 0004 Tubing for drain, ¢ 8/11 mm, per m
1569 0010 Tubing Strip
1577 0007 Set of 2 Valves for alkali reagent dispenser
1579 0005 Timer
1000 2720 Glass Vessel for steam generator
1000 2762 Rubbler Seal for steam generator
1000 3504 Printed Circuit Board Complete
1000 3505 Heater Coil including cover for steam generator,
230 V / 1600 W
1000 3743 Steam valve complete

1575 0025 Double Solenoid Valve for coolingwater, 230V

1564 0082 Fuse F 125 mA
1564 0043 Fuse T 500 mA
1564 0006 Fuse T10 A 1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

1582 0066 Water tubing with integral connectors

1563 0117 Reed relay switch
1582 0011 Tubing for alkali 8/13-5 reinforced

10.3 Kjeltabs
Mercury tablets are delivered in boxes of 500, all other types in
boxes of 1000.

15270001 Selenium, tablets with 1,5 g K 2 SO 4 + 7,5 mg Se

15270002 Selenium, tablets with 5 g K 2 SO 4 + 5 mg Se
15270003 Selenium, tablets with 3,5 g K 2 SO 4 + 3,5 mg Se
15270004 Mercury, tablets with 3,5 g K 2 SO 4 + 175 mg HgO
15270010 CT, tablets with 5 g K 2 SO 4 + 0,15 g CuSO 4 x 5 H 2 O +
0,15 g TiO 2

20
 15270018 Copper, tablets with 3,5 g K 2 SO 4 + 400 mg CuSO 4 x 5
H20
15270020 CT, tablets with 3,5 g K 2 SO 4 + 0,105 g CuSO 4 x 5 H 2 O +
0,105 g TiO 2
15270033 Mercury, tablets with 1,5 g K 2 SO 4 + 7.5 mg HgO
15270034 Copper, tablets with 1,5 g K 2 SO 4 + 150 mg CuSO 4 x 5
H20
15270048 Mercury, tablets with 3,5 g K 2 SO 4 + 175 mg HgO
15270056 NAS, tablets with 1 g Na 2 SO 4 + 0,05 g Se
15270057 KPC, tablets with 4,5 g K 2 SO 4 + 0,5 g CuSO 4 x 5 H 2 O
15270058 Special (AB24), tablets with 1,65 g K 2 SO 4 + 0,33 g
CuSO 4 x 5 H 2 O + 0,0165 g Se
15270059 Special (AB22), tablets with 4,75 g K 2 SO 4 + 0,075 g
CuSO 4 x 5 H 2 O + 0,10 g Se
15270060 Antifoam (AA00), tablets with 0,966 g Na 2 SO 4 + 0,029
g silicon + 0,005g Si
15270061 Auto CT (AA22), tablets with 1,5 g K 2 SO 4 + 0,045 g
CuSO 4 x 5 H 2 O + 0,045 g TiO 2
15270062 Special (AB64), tablets with 5,0 g K 2 SO 4 + 0,06 g Se
15270063 KS (AA47), tablets with 4,95 g K 2 SO 4 + 0,05 g Se
15270065 K/5 (AA23), tablets with 5 g K 2 SO 4

Other types are available upon request. However, those listed

above represent more than 90% of the catalyst tablets used
worldwide.

10.4 Manufacturer’s Name and Address

FOSS Tecator AB
Box 70
SE-263 21 Höganäs
Sweden

Int phone. +46 42 361500

Int fax. +46 42 340349
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden

21
22
This page is intentionally not used.

1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden
c) Switch on the power.
d) Turn on the cold water tap
Note: The water for the condenser and
steam generator will not flow until the
steam valve is in the open position
with the power on. It will stop
automatically when the valve is closed.
e) Open the valve for steam by pushing the
steam control handle on the front panel in
down position (Fig. 9).
After a couple of minutes steam is
generated. Let the distillation continue until
some water is collected in the receiver flask.
The system is then heated up.
g) If the platform with the receiver flask is in
the upper position (Fig. 10), move it to the
lower position. Close the steam valve on the
front panel.
11.4.3 Distillation
a) Remove the test tube and the receiver flask.
b) Place the tube with the first diluted Sample
to be distilled in its position and place the
receiver flask with the receiver solution on
the platform. To avoid contamination don’t
touch the glass outlet tube with your fingers.
Hold it by its plastic tubing if necessary.
c) Close the safety door.
d) Move the platform for the receiver flask to
its upper position.
e) Gently pull the alkali handle all the way
down to dispense about 50 ml of alkali (Fig
8).
f) Open the steam control and set the timer to
the appropriate distilling time (around 4
minutes).
g) Lower the platform for the receiver flask
and continue distillation for a few more
seconds to rinse the outlet tip.
Close the steam control.
h) Replace the test tube and the receiver flask
with the next set and continue in the same
manner with all the samples. When
removing a tube, the teflon pipe through
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden
which the steam enters the sample, should
be placed in the slot of the plastic holder
(Fig. 11). This makes it possible to replace a
tube without touching the teflon pipe which
will have traces of alkali on it.
11.4.4 Closing down
a) Do the daily maintenance according to
chapter 11.5.
b) Pull out the drain collector (Fig. 12) under
the tube holder and the platform for the
receiver flask and clean it with water. Wipe
the instrument clean from any spillage.
c) Switch off the power and close the water
tap.
11.5 Maintenance
This text is also avaliable as an instruction
10006458 which includes Maintenance Record
Charts to facilitate a record of your actions.
11.5.1 Daily
To avoid start up problems and to prolong the
lifetime of your system the procedures described
in this chapter should be performed every day
the unit is used.
11.5.1.1 Cleaning cycle
Connect a test tube half filled with distilled
water and a receiver flask into their positions.
Open the valve for steam and distil for 3
minutes, in order to avoid chemical residues to
remain in the lower part of the splash head.
11.5.1.2 Cleaning of unit
Clean the whole unit from any spillage with a
damp cloth or sponge.
11.5.1.3 Rubber adapter
Clean the adapter from all remaining residues
with a damp cloth or sponge, use warm water.
Also clean the splash shield from residues.
11.5.2 Weekly
In addition to the daily routines outlined above,
the following procedures should be performed
on a weekly basis, or as the need arises. Use the
Weekly Maintenance Record Chart provided to
keep a record of these operations.
11.5.2.1 Reagent tanks inspection
and cleaning
Check the tanks for: Signs of cracks or splitting.
Replace the tank if damaged. Crystals blocking
the air holes in the screw cap. To remove any
crystals wash the screw cap in clean warm water
until the crystals are dissolved, dry and replace.
11.5.2.2 Digestion tubes inspection
Check the rims of the digestion tubes for uneven
surface,cracks and chips. This type of damage
can cause leakage between the tube and the
rubber adapter leading to loss of recovery during
analysis. Look for scratches and star fractures on
the base of the tubes. These can lead to untimely
and unexpected breakages creating a safety
hazard to you and your colleagues and potential
damage to your digestion or distillation unit.
Discard all damaged tubes in the interest of
safety.
After some digestions the base of the tubes may
take on an off-white to greyish coloration. This
is quite normal and does not require the tubes to
be replaced.
11.5.2.3 Cleaning the safety door
Clean the safety door from any spillage with a
damp cloth or sponge.
11.5.3 Every one to three months
In addition to the routines outlined above the
following procedures should be performed every
one to three months, or as the need arises,
depending on usage. Use the Maintenance
Record Chart provided with the instruction to
keep a record of these operations.
Important!
If the rear panel is removed, there is a
grounding cable (yellow/green)
connected inside between the rear
panel and the main cabinet (lower
right corner). Be sure to reconnect
when replacing the panel.
11.5.3.1 Controlling the rubber
adapter
Remove the rubber adapter from the unit and
inspect it for scratches and cracks. Note also if
the rubber of the adapter has started to lose it
softness. If the adapter show signs of scratches,
cracks or that the rubber has started to lose its
softness the adapter has to be changed.
11.5.3.2 Controlling the alkali
volume
· Connect an empty test tube to the unit.
Mark the wanted volume with a pen on the
tube. Alternatively, the content can be
poured in a measuring cylinder.
· Close the safety door.
·
Switch on power.
· Gently pull the handle all the way down to
dispense the alkali.
· Check the volume a couple of times. The
amount of alkali is set to about 50 ml from
the factory. This volume can be reduced by
putting dispensing stops in the slot below
the alkali dispensing handle. Turn them 90°
to fix them in position fig. 13.
· After any adjustment, check the volume
again.
24
11.5.3.3 Cleaning the alkali pump.
Put approximately two litres of warm, 40°C,
distilled water in a beaker and connect it to the
system.Pump about half a litre of the water
through the alkali pump by pressing the alkali
handle. This procedure requires that the tube is
emptied when about 200 ml has been dispensed.
Replace the tube and continue the flushing.
11.5.3.4 Cleaning of the splash
head
Pour about 25 ml of water and the same amount
of concentrated acetic acid into a test tube and
distil for 5 to 10 minutes. Replace the tube with
a clean tube and continue to distil for another 5
minutes. Repeat this at least three times so no
acid residues will interfere with the analysis.
11.5.4 Depending on number of
analyses
The frequency with which you should carry out
the procedures in this chapter depends upon a
number of factors which are outside FOSS
Tecator AB’s control and are therefore difficult
to predict. In simple terms you will have to
judge the required frequency by physically
checking the situation in each case. To a large
extent the frequency will depend on two major
points.
1. The quality of the water used for steam
generation. For example tap water will
create more or less salt deposits depending
on its hardness. If deionised water is
used,cleaning will rarely be necessary, but
please remember that a certain level of
conductivity is required for correct
operation of the level pins (See trouble
shooting)
2. How well you have followed the guidelines
in the first three chapters of this text.
Regular and immediate cleaning of splashes
and spillage will create less problems.
Routine checking of connectors when the
reagents are replaced will limit the
likelihood of leakages.
1002 Kjeltecä System, User Manual, Rev. 2.3, Part no 1000 1535, FOSS Tecator AB, Sweden
11.7 Storage & transport
· TROUBLE SHOOTING* This requires the
fitting of a direct Feed Water System and
11.5.4.1 Cleaning of the steam must be carried out at the factory or by a 11.7.1 Lifting instructions 1002
generator certified FOSS Tecator AB service engineer
in your laboratory. This instrument is not equipped with handles or
Disconnect the power supply. Open the drain grips. Two persons are needed to lift the
valve for the generator. When empty, fill up the For information about preparation of chemicals instrument, following the instructions below:
generator with a solution of 100 g citric acid in and the Kjeldahl method please see the
800 ml water, preferable hot, by connecting the Application Note AN 300 supplied with your 1. Tilt the instrument slightly backwards, and
funnel to the steam generator drain. Suspend the system. lift and support the instrument as shown in
funnel so that is in higher position than the fig.16 to simplify and ensure a safe lift.
steam generator. Close the drain valve, whilst In FOSS Tecator ABs extensive list of
the funnel is still suspended above the steam Application Sub Notes you will find information 2. Weight 25 kg.
generator. on how to analyse the sample of your choice.
Please contact your FOSS Tecator AB Caution!
Alternative 1.Leave the solution in the steam representative for more details. Avoid getting your fingers pinched!
generator overnight, or until the generator vessel
is free from deposits. 11.6 Technical
specifications 11.8 Explanations to
Alternative 2.Connect the power supply. Place a illustrations
distillation tube and a receiver flask in their 11.6.1 Safety
positions and close the safety door. Switch on Fig 5
power and open the steam valve. Let the citric The insulation of external, inaccessible circuits Connections left to right.
acid solution boil for about five minutes. Close is reinforced. 1. Steam waste tubing
the steam valve and disconnect the power 2. Cooling water inlet
supply. 11.6.2 Environmental conditions 3. Steam generator drain
4. Water tank (for direct feed water systems
Caution The equipment is designed to be safe at least only)
If Alternative 2 has been chosen the under the following conditions: 5. Alkali inlet
solution will be extremely hot!
· Indoor use 6. Electric power cable
7. Equipotential connector
Open the drain valve and empty the steam · Altitude up to 2000 m.
generator.
Rinse the generator thoroughly with water using · Temperature 5°C to 40°C. Fig 6
Use tubing clamps to secure tubings.
the funnel again. When the vessel is clean and · Maximum relative humidity 80% for
temperatures up to 31°C decreasing linearly
rinsed, close the drain valve. Remove the funnel Fig 7
and put the drain tubing outlet back to its normal to 50% relative humidity at 40°C. Water connection.
position.
· Mains supply voltage fluctuations not
Fig 8
exeeding ± 10% of the rated voltage.
1. Power switch
11.5.5 Every Year · Transient overvoltage is according to
category II, which is normal for this type of
2. Timer
3. Steam control
Your local distributor offers Service Agreements equipment. 4. Alkali handle
in order to make your instrument reliable in
performance and safety.
· Pollution degree 2 5. Safety door.
Fig 11
As a minimum of care all tubings and connectors Resting position for the teflon tube.
should be inspected. Exchange if visible
damages can be seen.
25