OPERATION AND MAINTENANCE MANUAL

No. Item Maker Model Q'ty Remark

E54 BOD5 Apparatus Lovibond OxiDirect 1 set

3268 OF 4699 Namdo Engineering Co., Ltd.

 BOD-System
OxiDirect®

Instruction Manual GB

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 Content
1. The system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Illustrations/Equipment supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. The method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Biochemical oxygen demand (BOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 BOD sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Principle of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. BOD measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Sample volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Preparing the water sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Preparing the sample / brief summary . . . . . . . . . . . . . . . . . . . . . . . . . 10

4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Technical terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Setting up the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.6 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.8 Reading out measurement values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.9 Starting measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.10 Parameter menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.10.1 Setting date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.10.2 Autostart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.10.3 Replacing batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5. Interpreting the results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6. Checking the measurement system . . . . . . . . . . . . . . . . . . . . . . . . 19
7. Replacing the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8. Care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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 Content
9. Inductive stirring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.1 User instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.1.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.1.2 Instruction symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.2 Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.3 Equipment description and function . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.4 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.5 Magnetic stirring rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.6 Stirring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.7 Maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.8 Problems during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.8.1 The magnetic stirring rod rotates unevenly . . . . . . . . . . . . . . . . . . . . . . 26
9.8.2 The stirring rod swerves back and forth . . . . . . . . . . . . . . . . . . . . . . . . 26

10. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10.1 BOD system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2 Inductive stirring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

11. Accessories and spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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1. The System
1.1 Principle of operation
BOD is determined by measuring the pressure difference within a closed system
(respirometric BOD). The integrated memory saves a BOD value automatically every
24 hours for a test period of more than 2 days. For a period of 1 day a value is saved
every hour, for 1 to 2 days, every 2 hours.

1.2 Applications
Determination of BOD5 and BOD7, OECD 301F / biological degradability.
Other bio-technological applications.

1.3 Illustrations / Equipment supplied

■ 1 x BOD measuring device with integral bottle rack

■ 6 x BOD sensor
■ 6 x BOD bottles
■ 6 x seal cups (Gasket)
■ 6 x magnetic stirring rods
■ 1 x stirring system drive
■ 1 x stirring system controller
■ 1 x nitrification inhibitor (ATH)
■ 1 x potassium hydroxide solution (KOH solution, 45%)
■ 2 x overflow measurement flasks (157 ml and 428 ml)
■ 1 x instruction manual

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2. The Method
2.1 Biochemical Oxygen Demand (BOD)
The biochemical oxygen demand (BOD) of waste water, industrial effluents and surface
water is an expression for the amount of oxygen consumed by the decomposition of
organic matter in a biochemical process. BOD measurement is an important analytical
tool in determining the effects of effluents on water treatment plants and surface water
systems.

2.2 BOD Sensors

The OxiDirect® is a respirometric BOD measurement system, where BOD is determined
in the bottle itself, without prior dilution. This method offers a range of advantages,
compared with the so-called dilution method. The sample can be tested undiluted
form; the measurement range is wider; the amount of work involved is significantly
less.

2.3 Principle of Measurement

The BOD measurement unit, consisting of the sample bottle and the BOD sensor,
represents a closed system. In the bottle, above the sample itself, is a defined air
space. During the BOD measurement the bacteria in the sample consume the dissolved
oxygen in the sample. This is replaced by oxygen out of the air within the bottle, above
the sample. The carbon dioxide released at the same time is chemically bounded by
the potassium hydroxide in the seal gasket. This generates a decrease of pressure
within the system. This is measured by the BOD sensor and displayed as a BOD value
in mg/l O2 .

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3. BOD Measurement
3.1 Sample Volume
The sample volume is related to the expected BOD value. The OxiDirect ® is designed
to operate over the measurement ranges and sample volumes shown in the following
table, allowing for BOD measurement ranges of 0 - 4000 mg/l, without any dilution of
the sample.

Range BOD mg/l Sample volume in ml Drops ATH

0 – 40 428 10

0 – 80 360 10

0 – 200 244 5

0 – 400 157 5

0 – 800 94 3

0 – 2000 56 3

0 – 4000 21.7 1

Table 1

Note
The expected results should be in the upper half of the range. For example, if the
expected BOD value is 250 mg/l, select a measurement range of 0 - 400 mg/l and,
therefore, a sample volume of 157 ml, for best results.
For domestic waste it is generally safe to consider a BOD5 value which is approximately
80 % of the COD value.

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3.2 Preparing the Water Sample
1. Check the pH value of the effluent sample. The optimum pH value for biochemical
oxidation is between pH 6.5 and 7.5. If the pH value of the sample is higher or lower, it
should be pre-adjusted. Any significant deviation will result in a lower BOD value. If the
pH value is too high, it can be reduced by adding dilute hydrochloric acid (1 mol/l) or
dilute sulphuric acid (1 mol/l). If the pH value is low, it can be adjusted with a sodium
hydroxide solution (1 mol/l).
2. Mix the water sample well and allow to settle for a short while. It may also be advisable
to filter or homogenise the sample.
Depending on the nature of the effluent to be examined (e.g., paper mill effluents,
surface water, dairy wastes) the sample will need to be pre-treated. Samples containing
fibres should be homogenised; samples containing algae should be filtered. BOD
measurements will not be comparable unless the same pre-treatment is used. In the
event of different results, the pre-treatment should be checked.
3. Measure out precisely the sample volume required, using the appropriate overflow
measurement flask and pour the sample into the sample bottle (it may be helpful to use
a funnel for this). Ensure that the sample in the bottle contains a representative portion
of any solids in suspension. It is recommended that each sample should be tested
twice or three times. It is essential to measure the sample volumes very precisely;
otherwise, significant measurement errors may occur. Where two samples are generally
the same but have different amounts of suspended solids, different results may be
expected. If the difference between results is significant, the measurements should be
repeated.
Note
The OxiDirect® measurement system is designed to operate with the sample volumes
shown in Table 1 and the sample bottles supplied with the system (or as spare parts).
Different volumes or wrong sample bottle will lead to false results. We therefore
recommend strongly that you always measure the samples with the overflow
measurement bottle supplied. You should also use a funnel to transfer the sample to
the BOD bottle.
4. To inhibit nitrification, we recommend the addition of nitrification inhibitor B
( = Allyl Thiourea, or ATH). This is particularly important for the low measurement range
of 0 - 40 mg/l (for example, when checking discharges from effluent treatment plants).
The ideal volume of nitrification inhibitor B to be added will depend on the measurement
range - see Table 1.
Note
Nitrifying bacteria also consume oxygen. This consumption can occur within the first 5
days and is more likely with samples with low BOD levels. As a general rule, the BOD
measurement should not include the oxygen consumption caused by nitrifying bacteria
and this can be inhibited by using nitrification inhibitor B. This inhibitor suppresses the
activity of the bacteria by enzymatic inhibition, so that only the breakdown of organic
substances in the sample will be measured as the BOD value.
If it is desired to measure oxygen consumption resulting from nitrification (N-BOD),
carry out measurements of samples both with and without the use of nitrification inhibitor
and compare the results. The difference between the two BOD values will represent the
oxygen demand of the nitrifying bacteria.

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5. Add a clean magnetic stirring rod to each sample bottle and add 3-4 drops of 45%
potassium hydroxide solution to the seal gasket (this will absorb the carbon dioxide).
Then insert the seal gasket in the rack of the bottle.
Important
The sample must never come in contact with the potassium hydroxide solution.
Never use grease or any other lubricants as an additional sealing agent, for the BOD
sensors or for the seal gasket. Products of this kind may contain solvents which will
attack the sensor, resulting in severe damage to the plastic housing and even to a
failure of the sensor. The use of sealing greases and lubricants is not covered by our
guarantee !
6. Before measurement begins, the prepared sample must be brought to the desired
temperature (e.g. BOD5, 20 °C ). This can be achieved by placing the sample in a
thermostatically controlled cabinet, while stirring the sample continuously with the
inductive stirring system.
The OxiDirect ® has an optional “Auto-Start” function, which enables it to start with
samples at temperatures from 15° to 20°C. When this “Auto-Start” function is switched
on, the system checks at specific intervals to detect whether there has been a fall in
pressure in the BOD bottle and will not start the timer until a pressure drop is detected
(the timer will start to run at latest 3 hours after the BOD sensor has been initiated,
whether or not a fall in pressure has been noted).
7. Place the BOD sensors on the sample bottles and tighten carefully. This is extremely
important – the system must be completely air-tight. Then place the BOD bottle, with
the sensor screwed in position, into the bottle rack. This can be done in the
thermostatically controlled cabinet itself.
Alternatively, because of the user-friendly design of the OxiDirect ®, you can remove the
entire BOD unit, with its integral bottle rack, from the thermostatically controlled cabinet,
while leaving the inductive stirring system in the cabinet. There is no need to disconnect
the cabling. Once the BOD bottles have been placed in the rack, the system is positioned
over the inductive stirring system so that the 4 adjustment screws engage in the
associated recesses in the stirring system drive.
8. Start the measurement process (see Section 4).
9. Incubate the sample in accordance with the instruction (e.g. BOD5 for 5 days at 20 °C).

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3.3 Preparing the Sample / Brief Summary
• Estimate the measurement range for the sample under test and select the volume of
the sample (see Table 1).
• Carry out any essential pre-treatment of the sample (e.g., setting the pH value; filtering; etc.).
• Measure the volume of the sample precisely, using the overflow measurement flask
and transfer it to the BOD bottle, with the aid of a funnel. If necessary, add nitrification
inhibitor (see Table 1).
• Insert the magnetic stirring rod in the BOD bottle.
• Place 3-4 drops of KOH solution into the seal gasket. Then insert the gasket in the rack
of the bottle.
• Screw the BOD sensors to the sample bottles.
• Place the sample bottles in the bottle rack.
• Start the measurement process (see Section 4).
• Incubate the sample in accordance with the instructions (e.g. BOD5 for 5 days at 20 °C)

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4. Operation
4.1 Buttons

ESC - switch the unit on and off

ESC - quit sub-menus
- shut down an application
START - start measurements
Start +
READ - read and display the current value
(this is not saved !)
Read – Enter + - select the next completed / available head
- increase parameters
- - go back one head
- reduce parameters
ENTER - confirm input
- switch to next stage in a menu

4.2 Notes
Flicker of the display is normal. To ensure correct measurements the measuring
tasks got a higher priority than the routine serving the display.
If bottles have been added to the rack while switched off, the unit must be switched on
once for starting the measurement.
If bottles have been removed permanently from the rack while the electronics were off,
the unit should be switched on and off once, so that these places do not affect the life
span of the batteries.
The unit will switch itself off after approximately 45 seconds. To prolong battery life, the
unit should always be switched off immediately, after the current task has been
completed. For taking the required measurements the unit will work in the “background”
mode, with only the centre “minus” in the upper display being illuminated. Once the
measurement is completed, the unit will switch itself off again.
The battery capacity is monitored continuously. If the batteries are closed to the end of
their effective life, the display show “Lo” ”bAt”. At this point, the batteries should be
replaced (see : “Replacing Batteries”). Because a reliable evaluation of the battery level
cannot take place until the unit has been switched on for approximately 15 seconds,
the “switch off” sequence, during which “OFF” is displayed, may take a little longer if
the unit is switched off very shortly after it has been switched on.

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4.3 Technical Terms

Rapid read-out mode Operating condition, in which the OxiDirect ® displays the last
measurement value which has been stored and the period of
measurement of a head.

Read-out mode Operating condition, in which all stored measurement values for an
individual head can be displayed, together with the time of
measurement.

Start mode Operating condition, in which measurements can be started

Completed head A head which has completed its series of measurements

Free head A heads, where the series of measurements has been completed
and at least one values has been displayed in “read-out” mode
(see : “Reading Out Measurement Values”).

Background mode The OxiDirect® is carrying out measurements, or is waiting just before
a measurement execution time. However, the display is switched
off, except for the centre “minus” in the upper display. Before switching
on the unit, wait until the “background” mode has finished and the
display is completely blank.

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4.4 Displays

LoAd OxiDirect® has not located Provided at least one head is

a valid head available, check the contacts

LEDs These display the position of the head,

to which the values in the display apply

LED perma- Measurement completed

nently lit

LED flashes Measurement not yet completed

UFL “Underflow “ the BOD is lower Check that the sample bottle
than the allowed range is fully sealed against
(meaning below 0) the measurement head
Check tempering of the system

OFL “Overflow” the BOD exceeds the

upper limit of the chosen
measurement range

Lo bAt End of battery life Replace batteries

Measurement No valid preasure condition found for Check that the sample bottle
value flashes a start during the “Autostart” time is fully sealed with the
window measurement head
Check tempering of the system

F1 No measurement value available yet

F2 No “start” value available yet,

so no current figure can be calculated

F120 A fault has occurred during “Start” Do not remove a bottle or change
their places during the “Start”
procedure

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4.5 Setting up the Unit
The batteries are not in place for shipment. If necessary, take all samples from the rack,
turn the rack around and open the battery compartment. Place the three alkali-
manganese “Baby” cells (C-Size) in the battery compartment, making sure of correct
polarity. The unit should then be started automatically and will be in the “Date-Time”
sub-menu (see “Setting Date & Time”). If the unit does not switch on, or is not in this
sub-menu, switch to the “Date-Time” sub-menu as described in the instructions. Set
date and time and switch the unit off. Switch it on again and the unit will go into “Rapid
Read-Out” mode. Then switch the unit off again.

4.6 Switching On
Switch the unit on by pressing the “ESC” button. The OxiDirect® will now be in “Rapid
Read-Out” mode and will display the final value of the first completed measurement
which it finds (the “Position” LED will illuminate to indicate the position). If no completed
measurement is available, the “Position” LED will flash. The upper display will show the
time span (e.g., “ 5d” for BOD5, while the lower display will show the last value which
has been stored. If the display shows “F 1”, there is no stored value jet available. If no
value could be measured at the specified time, the display will show “-F- ”.
The “ + ” button is used to switch over to the position of the next completed
measurement, while the “ - ” button is used to select any head required. Positions
without a bottle in places cannot be selected.

4.7 Switching Off

The unit is switched off by pressing the “ESC” button, if it is in the “Rapid Read-Out”
mode. During the switch-off sequence, the upper display will show “OFF” followed by
the centre “minus”. During this time, no bottles must be taken from or added to the
rack. The switch-off sequence is finished when the display no longer shows “OFF” and
the centre “minus” has also disappeared. Do not push the “ESC” button during this
sequence. If you wish to switch the unit on again, it is essential to wait until at least two
seconds after the display is completely off.
If the unit is not in the “Rapid Read-Out” mode, it will be necessary to press the “ESC”
a number of times in order to switch off.

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4.8 Reading Out Measurement Values
Set the unit to “Rapid Read-Out” mode, select the desired position and press the
“ENTER” button. The unit will switch to “Read-Out” mode for the bottle you have
selected. The upper display will show the time of the measurement, the lower display
will show the corresponding stored measurement value. If the measurement period is
one or two days (for BOD1 and BOD2) the time of the measurement will be shown in
hours. If the measurement period is longer than 2 days (BOD3 , BOD4...) the figure
shown in the display will read in days. Time in hours is displayed in the form of “hxx” (for
example, “h48” for the last measurement value for BOD 2). Time in days is displayed as
“dxx” (for example, “d 5” for the last measurement value for BOD5 ).

4.9 Starting Measurement

Starting a new measurement will delete all stored data for the sensor!
Press the “START” key. The unit will switch to “Start” mode. It will then seek the first
free position. The lower display will show the measurement range which was used last
time, while the upper display will show the necessary sample volume. Use the “ + ” and
“ - ” key to change the position (the “ + ” key will select the next free position, while the
“ - ” key can be used to select any position).
Press “ENTER”. The “ + ” and “ - ” keys can now be used to select the measurement
range. Confirm the range selected by pressing “ENTER” again. The unit will now display
last used measurement time span. If this is not changed within 3 seconds (use the “ + ”
and “ - ” keys) this previous measurement duration is automatically adopted and the
measurement will start. Following a modification, this automatic start will no longer
operate. The “start” procedure can be stopped by pressing the “ESC” key.
If the unit does not find a free position, it will select some head. In this case, the display
will show “dEL ”. If you wish this head to be used, press the “START” key again. The
unit then changes to the selection of the measurement range.
Once a measurement has been started, the unit will indicates the next free position.
Pressing the “ESC” key will cause the unit to quit the “Start” mode and return to the
“Rapid Read-Out” mode.

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4.10 Parameter Menu
Press the “ENTER” key and keep it pressed. Switch the unit on. Once the lower display
has flashed 3 decimal points for approximately 3 seconds, release the “ENTER” key.
The unit is now in the “Parameter” menu and will initially display the “Date-Time” sub-
menu. Use the “ + ” and “ - ” keys to switch between the “Date-Time”, the “Autostart”
and the “Replace Batteries” sub-menu. Press the “ENTER” key to select the required
sub-menu. Leave the ”Parameter” menu by pressing the “ESC” key and return to the
“Rapid Read-Out” mode.
4.10.1 Setting Date & Time
Switch the unit to the “Parameter” menu and select the “Date-Time” sub-menu :
“Set” ”dAtE”. The unit will display “ dA” and the current year setting. Press the “ENTER”
key. The unit will now display “ dA” and the current date setting in the form of “MM.TT”
(MM = month and TT = day). Press the “ENTER” key. The unit will display “ ti” and the
time in the form of “hh.mm” (hh = hours and mm = minutes). Press the “ENTER” key.
The upper display of the unit will flash “JJ” and the lower display will show the year. Use
the “ + ” and “ - ” keys to increase or decrease the figures and store by pressing the
“ENTER” key.
Using the same method, set the figures for the month (the display shows “Mo”), the
day (the display shows “ dd”), the hour (the display shows “hh”), the “tens of minutes”
(the display shows “M”) and the single minutes (the display shows “m”). Finally, press
the “ENTER” key in order to execute. The unit will set its internal clock to these figures
and, if there was no fault, the display will show “iS” ” Set”.
Before finally confirming by pressing the “ENTER” key, you can go back by pressing the
“ESC” key or quit the “Date-Time” menu.

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4.10.2 Autostart
The “Autostart” function can be switched on or off. The setting which is selected will
apply to all the heads on the rack from now on.
In particular, when the “Autostart” function is switched off, an automatic start will also
take place immediately for those heads which had been initiated by the “Autostart”
function when it was switched on, but for which the “start” condition had not yet been
achieved. To change the setting go to the “Parameter” menu and select the sub-menu
: “Set” ”Auto”. The “ + “ key is then used, in the “Autostart” sub-menu, to switch on the
“Autostart” function. With the function switched on, the unit will display “On” ”Auto”
and can be switched off with the “ – “ key. Once the selection has been made, you may
quit the sub-menu by pressing the “ESC” key. This causes the new setting to become
effective.
4.10.3 Replacing Batteries
In order to replace the batteries without missing an intermediate measurement, make
sure the tool required to open the battery compartment is to hand, as well as the new
batteries (3 alkali-manganese “baby” cells (C-Size)).
Set the unit to the “Parameter” menu and select the “Replace Batteries” sub-menu
“Set” ”bAt”. Activate the menu by pressing the “ENTER” key. The unit will display “bAt”.
Press the “ENTER” key again. The display will flash, showing “bAt” ”chg”. Wait until the
display becomes dark - this may take up to 6 minutes. At this point the unit has
switched off.
The batteries must be replaced within the next 4 minutes : the unit should not be
without battery power for more than one minute. Take all the samples from the rack,
turn the rack around and open the battery compartment. As soon as the old batteries
have been removed, the new batteries must be inserted, so that they are in place and
able to power the unit within one minute. Then close the battery cover, replace all the
samples and switch the unit on. Once the unit has reached the “Rapid Read-Out”
mode, it can be switched off again.
If the unit goes automatically into the “Date-Time” menu after the batteries have been
replaced, this indicates that the power supply was interrupted for too long. It will then
be necessary to reset the date.

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5. Interpreting the Results
300

250

200

150

100

50
0
Start 1. Day 2. Day 3. Day 4. Day 5. Day

1. The BOD value on any particular day must be higher than that measured on the previous
day.
2. BOD values do not increase in a linear manner. The increase is always smaller than that
of the previous day.
3. If the BOD results increase in a linear manner, the sample has a higher BOD value than
expected when the sample was prepared.
4. If BOD results rise suddenly in the course of measurement, this may be the result of
nitrification.
5. If BOD results fall suddenly in the course of measurement, this may indicate that there
is an air leak in the system.
The information given in the previous pages refers in all cases to normal samples
(municipal wastes) and the normal behaviour of bacteria in the course of a BOD
measurement. However, special events are always possible, depending on the relevant
circumstances. For example, if there is a reading of zero after 5 days, this may mean
that there is a leak in the system, or severe inhibition.
In the case of industrial effluents, special circumstances will often occur. Effluents of
this kind may contain toxic substances and these must be removed from the sample,
or the sample must be diluted so that the measurement results are not too low. In
addition, nutrients (nitrogen; phosphate) and trace elements such as iron must be
present in sufficient concentrations; otherwise bacterial growth may be limited and
artificially low BOD values may be recorded. Where problems of this kind occur in the
course of measurement, each individual case must be considered and resolved on its
own particular merits.
For further information, please ask for our application reports.

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6. Checking the Measurement System
The following test systems are available for checking the OxiDirect® measurement system:
1) Quick-test-equipment
The Quick-test unit for BOD sensors is a test unit which enables a BOD sensor to be
subjected to a defined vacuum. It can therefore be used to carry out a speedy and
simple check on the correct operation of individual BOD sensors.
2) Calibration Set
The calibration Set enables a check to be carried out on all the components of the
OxiDirect ®. It consists of special reagent tablets, which generate a defined vacuum in
the sealed BOD bottle. With the calibration Set, it is therefore possible to check the
entire OxiDirect ® system for functionality and correct sealing.

7. Replacing the Batteries

When the batteries are low, “Lo” ”bAt ” will appear in the lower display. To change the
batteries, loosen the two security screws and remove the cover to the battery
compartment. Replace the old batteries with three new batteries (Type: Baby/C/LR14,
Alkali-Manganese) according to the procedure given in chapter “Operation -->
Parameter-Menu --> Replacing Batteries”.
All calibration data remain secure while the batteries are being changed.

8. Care and Maintenance

High-quality metal alloys are used for the contacts between the BOD sensors and the
bottle rack. If necessary, the contacts may be cleaned carefully with a soft cloth.
To compensate for any irregularities and to ensure optimum contact between the BOD
sensor and the bottle rack, the BOD measurement system has 4 levelling screws on its
base.
If necessary, the BOD base unit (including the bottle rack) and the BOD sensors can be
cleaned carefully with a soft cloth.
All parts which come into contact with the sample (BOD bottles; seal cups; magnetic
stirring rod) must be cleaned thoroughly after each measurement. The bottles must be
emptied completely and washed several times in hot water.
Where any cleaning agents, washing up liquids, etc., are used, the parts must be
rinsed thoroughly ! The residues of such agents can interfere with BOD measurements.

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9. Inductive Stirring System

Fig. 1: Inductive stirring drive with stirring controller

Stirring place

 Stirring drive

 Stirring controller

 Plug out

 Control cable

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9.1 User Instructions

9.1.1 Correct use

This inductive stirring system has been designed for stirring liquids in BOD bottles.

9.2.2 Instruction symbols

The following instruction symbols are used in this operating manual:

DANGER!

This sign refers to dangerous voltages

DANGER!

This sign refers to hazardous situations.

Risks to human life are indicated by the term ”LIFE HAZARD”

CAUTION!

This sign indicates risks to equipment and machinery

 INFORMATION

This sign indicates easier working practices

* Indicates an operating step

Indicates alternatives

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9.2 Safety Considerations
For your own safety, you should observe the following safety warning signs.
The safety warnings indicate a possible sources of danger. At the same time they
contain information on how correct action can avert danger. You will always find warning
signs attached to points of possible danger.

DANGER!

Magnetism.
Magnetic or metallic parts (e.g. data carriers, pacemakers, watches ...) can be
affected by magnetic fields.
Keep such parts away from the magnetic stirrer (2) and the magnetic stirring
rods

DANGER!

Supply voltage and supply frequency must be within the range specified for
the control unit (3)

CAUTION!

Do not use in hazardous locations

CAUTION!

General ambient conditions :

Stirring drive (2): -10 to +56 °C at 100% humidity.
Control unit (3): 0 to +40 °C at max. 80% humidity.
Avoid extreme temperature changes.
The control unit (3) must not be run in humid rooms, or set up in areas where
water may splash!

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CAUTION!

Do not place hot stirring vessels on top of the magnetic stirrer (2).
Maximum temperature : 56 °C.

CAUTION!

In case of repair, the equipment must only be opened by an authorised service

agent. Disconnect from mains before opening !

CAUTION!

Do not allow the magnetic stirring rod to come to rest in an alternating magnetic
field (e.g. in an unfilled stirring vessel when the stirring or mixing mode is
selected). Do not subject the magnetic stirring rod to a strong inverse magnetic
field or to strong impact shocks (e.g. by dropping it). This may result in
destruction of the magnetic stirring rod.

 INFORMATION

The length of the magnetic stirring rod must not exceed 40 mm.
Do not use elliptical stirring rods with a round cross-section.

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9.3 Equipment Description and Function
The stirring system has been designed for stirring liquids in standard BOD bottles. It
consists of an ultra-slim stirring drive (2) with 6 stirring points (1) and a separate stirring
controller (3). All the bottles can be removed from the rack without disturbing the stirring
drive (2). Several stirring drives (2) can be installed next to each other, saving space.
The stirring drive has no motor and is therefore wear-free. It is particularly suited to
continuous stirring in a incubator. It is hermetically sealed (fully protected from splashing
water) and can be used even in the roughest environments. The wide space between
the stirring points (1) ensures good ventilation of the stirring containers, even in a
incubator. The stirring drive (2) is controlled by a controller (3) with a pre-set speed.
When turned on, the soft start feature ensures a uniform start of the magnetic stirring
rods at half speed.
Every 40 seconds, the electronically controlled automatic monitor reduces the stirring
speed by 50%, re-centring the magnetic stirring rod in the middle of the bottle for
several seconds. This means that individual bottles may be “hot-swapped” or the rack
installed during operation.
The magnetic stirring rods are operated synchronously, preventing practically any
interference between them.

9.4 Start-up procedure

DANGER!
Supply voltage and supply frequency must be within the range specified for
the control unit (3)

DANGER!
Magnetism. Magnetic or metallic parts (e.g. data carriers, pacemakers,
watches ...) can be affected by magnetic fields. Keep such parts away from
the magnetic stirrer (2) and the magnetic stirring rods.

CAUTION!
Do not use in hazardous locations

CAUTION!
General ambient conditions:
Stirring drive (2): -10 to +56 °C at 100% humidity.
Control unit (3): 0 to +40 °C at max. 80% humidity.
Avoid extreme temperature changes.
The control unit (3) must not be run in humid rooms, or set up in areas where
water may splash !

The control unit (3) does not have an on-off switch. It is ready for use as soon
as it is plugged in.

* Connect the control cable (5) from the stirring drive (2) to the output
socket (4) of the control unit (3) while tightening the thumb-wheel.

* Plug the control unit (3) into the mains socket.

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9.5 Magnetic stirring rods
We recommend the use of PTFE-coated magnetic stirring rods.

 INFORMATION

The length of the magnetic stirring rod (8) must not exceed 40 mm.

9.6 Stirring

CAUTION!

Do not place hot stirring vessels on top of the magnetic stirrer (2).
Maximum temperature : 56 °C.

** Fill the bottles with the sample.

Place a magnetic stirring rod into every bottle.

* Place bottles in the BOD rack.

The control unit (3) is preset to operate at 320 rpm. The electronically controlled
automatic monitor reduces the stirring speed to about 200 rpm, re-centring
each magnetic stirring bar in the middle of the bottle for several seconds. This
means that individual bottles may be “hot-swapped” or the rack installed during
operation.

If you want to stop the stirring process:

* Disconnect the control unit (3) from the mains socket.

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9.7 Maintenance and Cleaning
The stirring drive (2) is maintenance-free.
The magnetic drive inside the housing is embedded in synthetic resin and is completely
watertight. Clean the surface of the stirring drive (2) at regular intervals. It may be
cleaned under running water. Alternatively, you may clean the stirring drive (2) with a
disinfectant solution suitable for use on PVC. Wipe the surface of the stirring controller
(3) using a damp cloth.

CAUTION!

In case of repair, the equipment must only be opened by an authorised service

agent. Disconnect from mains before opening !

9.8 Problems during Operation

9.8.1 The magnetic stirring rod rotates unevenly:

Some ageing of the stirring rod in time cannot be avoided. This may reduce its
magnetisation.

CAUTION!

Do not allow the magnetic stirring rod to come to rest in an alternating magnetic
field (e.g. in an unfilled stirring vessel when the stirring or mixing mode is
selected). Do not subject the magnetic stirring rod to a strong inverse magnetic
field or to strong impact shocks (e.g. by dropping it). This may result in
destruction of the magnetic stirring rod.

* Replace it by a new one.

9.8.2 The stirring rod swerves back and forth:

Swerving movements of the magnetic stirring rod may be caused by irregularly shaped
forms of the bottle. This may occur, for instance, in the case of BOD bottles with a
convex bottom if the bottom is shaped irregularly or asymmetrically.

* Replace the bottle by a new one.

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10. Technical Data

10.1 BOD System

Type OxiDirect®

Measurement principle Manometric; mercury-free; electronic pressure sensor

Ranges 0 - 40, 0 - 80, 0 - 200, 0 - 400, 0 - 800, 0 - 2000, 0 – 4000 mg/l

[mg/l O2]

Applications BSB 5, BSB7, OECD 301 F ...

Result display BSB [mg/l]; 4 - digits; 7 - segment LED

Measurement BOD-range, volume, duration, display time of measurement

parameter display

Measurement period User-selectable, between 1 and 28 days

Auto result storage up to 28 results, depending on measurement period

Storage intervall – hourly (1 day);

– every 2 hours (2 days);
– daily (3-28 days)

Automatic start function – After temperature equalisation of samples

– can be switched off

Power supply 3 alkaline-manganese batteries

Battery life 1 year (normal use as BOD5 meter – max. one reading a day);
early warning before battery fails

Clock Real-time clock

Protection class IP54 (sensor head)

Dimensions 375 x 195 x 230 mm

(L x W x H) included stirring unit

Housing ABS

Approval CE

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10.2 Inductive Stirring System

Type Inductive Stirring System

Stirring volume 6 BOD bottles

Stirring power 7W

Rotation speed 320 rpm

(briefly reduced to 200 rpm every 40 s)

Dimensions (W x D x H) 270 x 180 x 25 mm

Distance between 88 mm
stirring points

Weight (stirring drive) 1800 g

Housing material PVC

General Ambient Conditions -10 to +56 °C at 100 % humidity

Operating voltage 20 V max.

Control cable 2m

Protective system IP 68 (DIN 40050)

Stirring controller
230 V version
115 V version
Permanent ambient conditions
Protection class
220 – 240 V / 10 V / 50 - 60 Hz, protection class II,
Thermosicherung, CE-Zeichen
110 – 120 V / 10 V / 50 - 60 Hz, protection class II,
thermal feature
0 to + 40 °C at max. 80 % humidity
IP 20 (DIN 40050)

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11. Accessories and Spare Parts List
Article Order code

Replacement BOD sensor 444430

Replacement BOD base unit 444433

Stirring controller 444413

Inductive stirring drive 444401

Quick-test-equipment 418327

Calibration Set 418328

Potassium hydroxide solution (50 ml) 418634

Nitrification inhibitor B (50 ml) 418642

BOD sample bottle 418644

Seal cup (gasket) 418636

Diagram pad 418663

Magnetic stirring rod 418637

Magnetic stirring rod remover 418638

Overflow measuring flask, 428 ml 418660

Overflow measuring flask, 360 ml 418659

Overflow measuring flask, 244 ml 418658

Overflow measuring flask, 157 ml 418657

Overflow measuring flask, 94 ml 418656

Overflow measuring flask, 56 ml 418655

Overflow measuring flask, 21, 7 ml 418664

Thermostatically controlled incubators see general catalogue

Thermostatically controlled incubators with glass door see general catalogue

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