Endress + Hauser Operating Instructions TOCII CA72TOC Analyzer for online determination of TOC

BA00448C/07/EN/13.15 71305431 Products Solutions Services Operating Instructions TOCII CA72TOC Analyzer for online determination of TOC in aqueous media using thermic catalytic combustion Document information Warnings The structure, signal words and color coding applied to safety information comply with the requirements of ANSI Z535.6 ("Product safety information in product manuals, instructions and other collateral materials"). Structure of information ! DANGER Cause (/consequences) Consequences of noncompliance (if applicable) ‣ Corrective action ! WARNING Cause (/consequences) Consequences of noncompliance (if applicable) ‣ Corrective action ! CAUTION Cause (/consequences) Consequences of noncompliance (if applicable) ‣ Corrective action NOTICE Cause/situation Consequences of noncompliance (if applicable) ‣ Action/note Meaning This symbol alerts you to a dangerous situation. If you do not avoid this dangerous situation, it will result in death or serious injury. This symbol alerts you to a dangerous situation. If you do not avoid the dangerous situation, it may result in death or serious injury. This symbol alerts you to a dangerous situation. Failure to avoid this situation can result in minor or more serious injuries. This symbol alerts you to situations which may result in damage to property. Symbols used Additional information, tips Permitted or recommended Forbidden or not recommended Endress+Hauser TOCII CA72TOC Table of contents 1 Basic safety instructions . . . . . . . . . . . . . 5 6 Commissioning . . . . . . . . . . . . . . . . . . . 34 1.1 1.2 1.3 1.4 1.5 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . 5 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Workplace safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6.1 6.2 2 Incoming acceptance and product identification . . . . . . . . . . . . . . . . . . . . . . 7 2.1 2.2 2.3 2.4 Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . 7 Product identification . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2.1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2.2 Product identification . . . . . . . . . . . . . . . . . 7 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 8 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . 9 3.1 3.3 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . 9 3.1.1 Methods of installation . . . . . . . . . . . . . . . . 9 3.1.2 Compressed air and water supply . . . . . 10 3.1.3 Gas flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1.4 Environment . . . . . . . . . . . . . . . . . . . . . . . 10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.2.1 Mounting sequence . . . . . . . . . . . . . . . . . 11 3.2.2 Wall mounting with a pivoting frame . . 11 3.2.3 Mounting on a base frame . . . . . . . . . . . 12 3.2.4 Mounting the CO2 adsorber . . . . . . . . . . 12 3.2.5 Connecting the media . . . . . . . . . . . . . . . 13 3.2.6 Preparing the chemicals . . . . . . . . . . . . . 15 Post-installation check . . . . . . . . . . . . . . . . . . . . . 19 6.5 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 6.2.1 Commissioning sequence . . . . . . . . . . . . . 34 6.2.2 Updating the analyzer software . . . . . . . . 35 Programming mode . . . . . . . . . . . . . . . . . . . . . . . . 37 6.3.1 Menu SETTING - RANGE DATA . . . . . . . 37 6.3.2 Menu SETTING - BASIC DATA . . . . . . . . . 39 6.3.3 Menu SETTING - ALARM LIMITS . . . . . . 40 6.3.4 Menu SETTING - SET CLOCK . . . . . . . . . . 41 6.3.5 Menu SETTING - SET BRIGHTN./ CONTR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.3.6 Menu SETTING - MEASURING SITE . . . . 42 6.3.7 Menu LISTS - SHOW COMPLETE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6.3.8 Menu LISTS - ALARM RECORD . . . . . . . . 43 6.3.9 Menu LISTS - MAINTENANCE RECORD . 45 6.3.10 Menu LISTS - MIN MAX AVERAGE . . . . 47 6.3.11 Menu LISTS - RECORD ALL DATA . . . . . . 47 6.3.12 Menu TEST - INPUT TEST . . . . . . . . . . . . 49 6.3.13 Menu TEST - OUTPUT TEST . . . . . . . . . . . 50 6.3.14 Two-channel: external changeover . . . . . 51 6.3.15 Two-channel: time-controlled changeover . . . . . . . . . . . . . . . . . . . . . . . . . 53 Optimizing the analyzer . . . . . . . . . . . . . . . . . . . . . 55 6.4.1 Adjusting the measuring range . . . . . . . . 55 6.4.2 Influence of dosing volume (pump P2) on the measuring signal . . . . . . . . . . . . . . 55 6.4.3 Operating the analyzer with high salt loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 4 Electrical connection . . . . . . . . . . . . . . . 20 7 Diagnostics and troubleshooting . . . . 60 4.1 7.1 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 4.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Preparing to wire . . . . . . . . . . . . . . . . . . . 4.1.2 Power distribution . . . . . . . . . . . . . . . . . . 4.1.3 Signal connection . . . . . . . . . . . . . . . . . . . 4.1.4 Power unit . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 Distributor connection . . . . . . . . . . . . . . 4.1.6 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Post-connection check . . . . . . . . . . . . . . . . . . . . . 5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . 28 5.1 5.2 5.3 Operating elements . . . . . . . . . . . . . . . . . . . . . . . Display and keypad . . . . . . . . . . . . . . . . . . . . . . . . Operation during measuring mode . . . . . . . . . . . 5.3.1 Recording mode . . . . . . . . . . . . . . . . . . . . 5.3.2 Spot view . . . . . . . . . . . . . . . . . . . . . . . . . . Standby mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 5.4 Endress+Hauser 20 20 21 23 25 26 26 27 6.3 6.4 28 29 31 31 32 33 3 TOCII CA72TOC 8 Maintenance . . . . . . . . . . . . . . . . . . . . . .65 8.1 8.2 8.3 8.4 8.5 Cleaning the housing . . . . . . . . . . . . . . . . . . . . . . . 69 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Topping up reagents . . . . . . . . . . . . . . . . . . . . . . . 70 Replacing the standard . . . . . . . . . . . . . . . . . . . . . 71 Entering the concentration of the standard solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 8.6 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 8.7 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 8.7.1 Replacing the hoses on pumps P1 and P4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 8.7.2 Replacing the hose on pump P2 . . . . . . . 83 8.7.3 Replacing the hose on pump P3 . . . . . . . 87 8.7.4 Adjusting pump P2 . . . . . . . . . . . . . . . . . . 92 8.7.5 Cleaning dilution water pump P5 . . . . . . 96 8.8 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 8.8.1 Adjusting the analyzer . . . . . . . . . . . . . . . 97 8.8.2 Calibrating the analyzer . . . . . . . . . . . . . 100 8.8.3 Empty volume dosing . . . . . . . . . . . . . . . 102 8.8.4 Adjustment pH sensor . . . . . . . . . . . . . . 105 8.9 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 8.9.1 Screen flush . . . . . . . . . . . . . . . . . . . . . . . 109 8.9.2 Power flush . . . . . . . . . . . . . . . . . . . . . . . 111 8.9.3 Bypass screen . . . . . . . . . . . . . . . . . . . . . . 113 8.9.4 Strip and separation chamber . . . . . . . . 115 8.9.5 Opening the circuit . . . . . . . . . . . . . . . . . 119 8.9.6 Combustion pipe . . . . . . . . . . . . . . . . . . . 121 8.9.7 Leakage test . . . . . . . . . . . . . . . . . . . . . . . 128 8.10 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 8.10.1 Replacing the acid filter . . . . . . . . . . . . . 131 8.10.2 Replacing the gas filter . . . . . . . . . . . . . . 133 8.10.3 Replacing the O2 filter . . . . . . . . . . . . . . 135 8.10.4 Replacing the heated salt trap . . . . . . . . 137 8.10.5 Replacing the filter pads in the ventilators . . . . . . . . . . . . . . . . . . . . . . . . 141 9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .142 9.1 9.2 9.3 9.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . 145 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 10 Accessories . . . . . . . . . . . . . . . . . . . . . .147 11 Technical Data . . . . . . . . . . . . . . . . . . .148 11.1 11.2 11.3 11.4 11.5 11.6 11.7 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Performance characteristics . . . . . . . . . . . . . . . . 149 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Mechanical construction . . . . . . . . . . . . . . . . . . . 149 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . .150 4 Endress+Hauser TOCII CA72TOC Basic safety instructions 1 Basic safety instructions 1.1 Personnel requirements ‣ Installation, commissioning, operation and maintenance of the measuring system may ‣ ‣ ‣ ‣ be carried out only by specially trained technical personnel. Trained personnel must be authorized for the specified activities by the system operator. Electrical connection must only be carried out by a certified electrician. Technical personnel must have read and understood these Operating Instructions and must adhere to them. Measuring point faults may only be rectified by authorized and specially trained personnel. Repairs not described in the Operating Instructions provided may only be carried out directly by the manufacturer or by the service organization. 1.2 Designated use The analyzer is a compact thermo-catalytic analytical measurement system. It is designed to monitor the TOC content of industrial and municipal wastewater. The device is particularly suitable for the following applications: • Monitoring of industrial wastewater, in the inlet and outlet • Control of process wastewater • Monitoring of surface run-off in industrial systems • Monitoring of surface run-off in airports • Municipal wastewater monitoring • Recording the carbon load for nutrient dosing Any other use than the one described here compromises the safety of persons and the entire measuring system and is not permitted. The manufacturer is not liable for damage caused by improper or non-designated use. NOTICE Applications which do not comply with specifications Possibility of incorrect measurements and faults, including failure of the measuring point ‣ Use the product only in accordance with the its specification. ‣ Pay attention to the technical data on the nameplate. 1.3 Workplace safety As the user, you are responsible for complying with the following safety conditions: • Installation instructions • Local prevailing standards and regulations. 1.4 Operational safety ‣ Before commissioning the entire measuring point, check all the connections. Ensure that ‣ ‣ ‣ Endress+Hauser electrical cables and hose connections are not damaged. Do not operate damaged products and secure them against unintentional commissioning. Mark the damaged product as being defective. If faults can not be rectified, the products must be taken out of service and secured against unintentional commissioning. Do not touch any rotating pump parts. 5 Basic safety instructions TOCII CA72TOC 1.5 Product safety The product is designed to meet state-of-the-art safety requirements, has been tested and left the factory in a condition in which it is safe to operate. The relevant regulations and standards have been met. 6 Endress+Hauser TOCII CA72TOC Incoming acceptance and product identification 2 Incoming acceptance and product identification 2.1 Incoming acceptance • Make sure the packaging is undamaged! • Inform the supplier about any damage to the packaging. Keep the damaged packaging until the matter has been settled. • Make sure the contents are undamaged! • Inform the supplier about damage to the contents. Keep the damaged products until the matter has been settled. • Check the delivery for completeness. Check it against the delivery papers and your order. • The packaging material used to store or to transport the product must provide shock protection and humidity protection. The original packaging offers the best protection. Also, keep to the approved ambient conditions (see "Technical data"). • If you have any questions, please contact your supplier or your local sales center. 2.2 Product identification 2.2.1 Nameplate The nameplate bears the following information: • Manufacturer data • Order code (device version) • Serial number • Measuring range • Outputs and communication • Power supply • Degree of protection • (Permitted) ambient conditions Compare the data on the nameplate with your order. 2.2.2 Product identification To establish your product version, enter the order code from the nameplate into the search field at the following address: www.products.endress.com/order-ident Endress+Hauser 7 Incoming acceptance and product identification 2.3 TOCII CA72TOC Scope of delivery The scope of delivery comprises: • 1 analyzer CA72TOC • Accessories for leak check • Tool kit to remove the glass ball and the media • Accessories for acid filter • Kit for commisioning of stripper and separation chamber • Accessories for combustion furnace maintenance • Hose kit • 1 canister 5 liter • 2 canisters 2 liter • Key for door lock • Connection box EMV • Measuring glas 10 ml • Sponge • Safety glasses • Gloves, acid-proof and base proof • Protective gloves, heat-resistant • Silicone grease • Operating Instructions If you have any questions, please contact your supplier or your local sales center. 2.4 Certificates and approvals Declaration of conformity The product meets the requirements of the harmonized European standards. It thus complies with the legal requirements of the EC directives. The manufacturer confirms successful testing of the product by affixing the 4 symbol. CSA C/US General Purpose (optional) The device meets the requirements of "Class 8721 06, laboratory equipment, electrical; Class 8721 86, electrical equipment for laboratory use - certified to US standards" for indoor use. Certificate no.: 2577401 Electrical safety In compliance with IEC 61010-1, protection class I, Installation category II. Fluctuations in the supply voltage may not exceed 10 percent of the nominal voltage. 8 Endress+Hauser TOCII CA72TOC Installation 3 Installation 3.1 Installation conditions 3.1.1 Methods of installation The analyzer can be mounted in three ways: • As a standalone desktop unit • Mounted to the wall (option F1) • Mounted on a base frame (option F2) a0023087 Fig. 1: Dimensions in mm (inch) Mount the device in such a way that it can also be accessed from the rear for maintenance purposes. Endress+Hauser 9 Installation TOCII CA72TOC 3.1.2 Compressed air and water supply When operating the analyzer, use only CO2-free air. The air must be dry and oil-free and must meet the following conditions: • < 3 ppm CO2 • < 3 ppm hydrocarbons • The pressure must be 2 bar (29 psi) constantly. • The pressure tolerance is ±5 %. • The required quantity of compressed air is: – 600 l/h (21.2 ft3/hr) for the CO2 adsorber gas generator (Domnick Hunter) – 60 l/h (2.12 ft3/hr) for the soda-lime CO2 scrubbers • The compressed air supply must be fitted with a CO2 scrubber (inlet pressure 4 to 10 bar (58 to 145 psi) and a pressure regulator. • Connection: 4/6 mm DN The water is connected via a 6/8 mm DN or G3/8 coupling. The pressure must be between 2 and 4 bar (29 to 58 psi) (for version with "sample predilution": 3 ±0.2 bar (43.5 ±3 psi)). In the version with sample predilution, use de-ionized water (DI water) or drinking water with a water hardness level < 10 °dH (< 179 ppm CaCO3) for the dilution water. 3.1.3 Gas flow When operating the analyzer, use only CO2-free air. Primary pressure at the manometer: 2 bar (29 psi). Circuit gas The flowmeter for the circuit gas is used to perform function checks and is set at the factory. The flow rate during operation is 0.7 to 1.2 l/min (1.5 to 2.5 ft3/hr). Carrier gas The volume flow for the carrier gas is regulated using a precision restrictor. The flow rate is approx. 0.8 l/min (1.7 ft3/hr) at a primary pressure of 2 bar (29 psi). Stripping gas The volume flow for the stripping gas is also regulated using a precision restrictor. The flow rate is approx. 0.15 l/min (0.3 ft3/hr) at a primary pressure of 2 bar (29 psi). 3.1.4 Environment • The analyzer requires a drain beneath the device. Use a 6/8 mm drain pipe made of PTFE. No backpressure should form in the drain. • An exhaust gas connection is required in enclosed spaces. Halogens or other vapors may not build up in this area. No backpressure should form in the 4/6 mm exhaust gas tube. • Ambient temperature range: 5 to 35 °C (41 to 95 °F) • Humidity: 20 to 80 %, non-condensating • Pollution degree 2 • The analyzer must be accessible from the front and rear. •  2000 m (6500 ft) above sea level • No direct sunlight 10 Endress+Hauser TOCII CA72TOC Installation 3.2 ! Installation WARNING Danger! Risk of electric shock! ‣ Do not connect the analyzer to the power grid before all the installation work has been completed and the liquid and gas media are connected. ‣ To connect the analyzer to the electricity supply, follow the instructions in the "Electrical connection" section . 3.2.1 Mounting sequence 1. Mount the analyzer on the base frame, on a table or in the pivoting frame. 2. Mount the EMC junction box (right-hand side of device). 3. Mount the reagent tray under the analyzer. 4. Mount the vent on the sample conditioning system (PA-2 / PA-3 or PA-9 only). 5. Connect the media (see the "Connecting the media" section). 6. Establish the electrical connections (see the "Wiring" section). 3.2.2 Wall mounting with a pivoting frame In the "Wall-mount" version, the analyzer is mounted to the wall with a pivoting frame. a0014227 Fig. 2: Pivoting frame for wall-mounting, dimensions in mm (inch) All bore holes for wall-mounting have a diameter of 8.5 mm (0.33"). Endress+Hauser 11 Installation TOCII CA72TOC 3.2.3 Mounting on a base frame In the "Base frame" version, the analyzer is mounted on a base frame. Mount the device in such a way that it is also accessible from the rear for maintenance purposes. .4) 62 0( 24 .4) 812 (32.0) 62 24 0( mm (inch) a0013913 Fig. 3: 3.2.4 Mounting on a base frame Mounting the CO2 adsorber • Position the CO2 adsorber gas generator (Domnick Hunter) on the ground or mount it on the wall in accordance with the enclosed drawing. • Mount the soda-lime CO2 scrubber in accordance with the enclosed Operating Instructions BA01243C/07/EN 12 Endress+Hauser TOCII CA72TOC Installation 3.2.5 Connecting the media 1 12 2 3 4 5 6 11 10 9 8 7 a0012643 Fig. 4: 1 2 3 4 5 6 7 8 9 10 11 12 Endress+Hauser Connections on the left side panel Power cable Gas outlet Gas connection Water connection Bypass rinse water External grounding Standard C2 connection Standard C1 connection Acid connection Condensate drainage Sample supply Sample drainage 13 Installation TOCII CA72TOC Sample supply Sample is supplied via a 3/8" connection on the left side panel (item 11). Sample conditioning Inlet connection (mm / inch) Outer diameter Drain connection (mm / inch) Outer diameter PA2 40 / 1.57 50 / 1.97 PA3 20 / 0.79 30 / 1.18 PA9 20 / 0.79 32 / 1.26 Analyzer sample drainage Sample is drained off unpressurized via a DN 6/8 mm hose connection (compression fitting) on the left side panel (item 12) into an open channel or pipe. Route the hose in such a way that backpressure cannot form. Condensate drainage Condensate is drained off without pressure via a hose gland (PE, DN 1.6/3.2 mm, scope of delivery) on the left side panel (item 10): • into a collecting vessel, • into an open channel or • into a pipe. The condensate discharge is acidic (pH value = 2 to 2.5). Route the hose in such a way that backpressure cannot form. Acid connection Place the acid cistern in the reagent tray. Connect the acid hose to the left side panel (item 9). Connecting the standards Put the standard containers in the holders on the left side panel. Connect the standards to the left side panel (C1 to item 8 and C2 to item 7). Gas outlet Gas escapes via a hose gland (DN 4/6 mm) on the left side panel (item 2). Ensure that there is adequate ventilation in the room, or remove the exhaust gas from the room via a hose (DN 4/6 mm). The end of the hose must be positioned in such a way that it is not under pressure and is protected from frost. 14 Endress+Hauser TOCII CA72TOC Installation 3.2.6 ! Preparing the chemicals WARNING Accidents with chemicals can kill, blind, burn, or damage lungs. Many chemicals are poisonous or corrosive; some are explosive, by themselves or in combination. Others are hazardous because they can be absorbed easily through skin or the respiratory system. ‣ When working with any chemicals, always observe the precautions in the section "Precautions regarding use of chemicals". The analyzer requires the following chemical solutions: • Stripper solution Nitric acid HNO3 (CAS: 7697-37-2) conc. 25 % Once it has been diluted accordingly, this acid is used to acidify the sample. This converts the carbonate ion CO32 into CO2 and removes the dissolved CO2 from the solution (TIC stripping). • Parent solution Potassium hydrogen phthalate (KHP (CAS: 877-24-7)) with a concentration of 5 000 mg TOC/l This parent solution for calibrating and adjusting the analyzer is used as a diluted standard in the measuring range from 0 to 600 mg TOC/l. In the event of high KHP concentrations and sample acidification (pH < 2.5), there is the risk of KHP precipitating in the solution. • Parent solution Citric acid (CAS: 5949-29-1) with a concentration of 100 000 mg TOC/l This parent solution for calibrating and adjusting the analyzer is used as a diluted standard in the measuring range from 600 mg TOC/l onwards. The stripper solution and the parent solutions are available from Endress+Hauser (see "Accessories" chapter). Specifying the standard concentrations The right choice of standard concentration is key to the accuracy of the measurement method. Before specifying the concentrations of the standard solutions, determine the concentration range in which the device is expected to measure. The most common concentrations should be covered by the standard solutions. Please note, however, that there should be a concentration ratio of between 1:4 and 1:20 between the two standard solutions. If a limit value is to be monitored, it makes sense for the concentration of a standard to correspond to the concentration of the limit value, as this guarantees the greatest precision when monitoring. Please note that there is no method of TOC measurement that can provide accurate measurement results over a span greater than 1:30. Example: Concentration to be measured: Most frequent concentration: Limit value to be monitored: 3 to 300 mg/l 50 to 150 mg/l 200 mg/l 20 and 200 mg/l should be selected here as the standard solutions. The system can then measure accurately in the range from 10 to 300 mg/l (taking the measuring range of the system into account). A higher measured value deviation can be expected below a concentration level of 10 mg/l and above a concentration level of 300 mg/l. Endress+Hauser 15 Installation TOCII CA72TOC Precautionary measures when working with chemicals • Carefully read the "Material Safety Data Sheet" (MSDS) that is supplied with every chemical to determine the hazards posed and what precautionary measures have to be taken. If you are not sure what risks are associated with the chemical, please ask appropriately qualified experts. • Never prepare chemicals on your own. You may need assistance in the event of an accident. For this reason, always make sure that someone is close-by. Only prepare chemicals in a properly equipped laboratory. • When preparing chemicals always wear protective goggles, rubber gloves and a rubber apron. In addition, wear a dust mask or face shield when working with fine-powder chemicals. • Chemicals or solutions that are used with the analyzer (or another process analysis device) should never be inhaled, tasted or swallowed. • When preparing solutions, you must always label the containers appropriately, indicating the contents and the date of preparation. Dispose of unlabeled or expired solutions in accordance with local regulations and guidelines. • Some chemicals are very reactive when combined with other substances or dissolved in water and cause explosions, fire or heat to occur, or dangerous gases, foams or sprays to be released. Avoid the risk of dangerous accidents occurring: If you do not know how certain chemicals react, make sure you do not mix them with other substances. Never mix chemicals that are known to react severely. Reagent quality Reagent quality can affect the accuracy of measurements. Only use high-quality reagents. For this reason, follow the steps outlined below to ensure reagent quality. • For 10, 100, and 500 mg/l units, use the best grade of reagents. For 1,000, 5,000, and 10,000 mg/l units, ordinary commercial grade acids and persulfate are suitable. For the KHP calibration standard, use reagent grade or better for all units. • Rinse all glassware and plastic containers thoroughly with deionized water. To achieve the best results, we recommend washing them once more with acid before use and rinsing them thoroughly with deionized water. • Use good scales and weigh the standard as accurately as possible before mixing. Keep containers closed to prevent contamination and deterioration. • Accurate preparation of the calibration standard is essential for accurate calibration of the analyzer. Inaccurate preparation of the calibration standard will result in a faulty calibration, which in turn will yield incorrect results. Preparing the parent solution using potassium hydrogen phthalate ! CAUTION Potassium hydrogen phthalate (KHP) can irritate the skin and cause problems with the eyes or respiratory channel. ‣ Do not inhale the powder and do not attempt to ever swallow any of the solution prepared. Shelf life: Storable parent solutions with concentrations of 5,000 mg/l are stable for 12 months if stored in a cool, dark place at 4 to 8 °C (40 to 46 °F). Prepared standard solutions must be used within four weeks even if stored in a cool, dark place. Concentrations: depends on the application. 16 Endress+Hauser TOCII CA72TOC Installation Procedure: For an organic carbon solution with a concentration of 5,000 mg/l, use a 1-liter volumetric flask to dissolve 10,627 g of p.a. KHP in 500 - 700 ml deionized water (other concentrations of the solution can be found in the following table). Once the chemical has dissolved, fill the volumetric flask up to the mark. Stir the solution once more. Label the container, indicating the contents and the date of preparation. mg/l carbon g KHP Volume 5.000 10,627 1l 1.000 2,1254 1l 500 1,0627 1l 100 0,21254 1l 10 0,021254 1l The solution with a concentration of 5,000 mg/l is stable (particularly when stored in a cool, dark place). It is recommended to perform serial dilutions on the basis of a standard substance of 5,000 mg/l to reduce the concentrations if needed. Example: • If 10 ml of a solution with a concentration of 5,000 mg/l is diluted with 90 ml deionized water, this results in a concentration of 500 mg/l. • If 10 ml of a solution with a concentration of 500 mg/l is diluted with 90 ml deionized water, this results in a concentration of 50 mg/l. • If 10 ml of a solution with a concentration of 50 mg/l is diluted with 90 ml deionized water, this results in a concentration of 5 mg/l. Serial dilution is the preferred method for creating lower concentrations. This is instead of diluting 1 ml of the 5,000 mg/l solution with 99 ml of deionized water. The latter method can result in measurement errors. NOTICE Please note the following: ‣ Storable parent solutions with concentrations of 1,000 and 5,000 mg/l are relatively stable for several weeks at room temperatures. Parent solutions must be stored in cool dark place. ‣ In the case of a solution with a concentration of 10 mg/l, on the other hand, the quality starts to deteriorate at room temperature within 3 to 5 days. For improved stabilization of KHP standard solutions, nitric acid or sulfuric acid can be used for acidification purposes. Use 4 ml of the 25% nitric acid (HNO3) or 4 ml of the 20% sulfuric acid (H2SO4) per liter. ‣ If parent solutions with a high KHP content acidify, there is the risk of the KHP precipitating. ‣ Make sure to keep the container with the crystalline KHP sealed at all times. If the crystalline KHP comes into contact with the air, it absorbs water very quickly and must be dried before use. Otherwise you will get inaccurate measurements since the concentration of carbon is lower in the hydrous salt. KHP that has come into contact with air must be dried for one hour at 105 °C (221 °F). Endress+Hauser 17 Installation TOCII CA72TOC Preparing the parent solution from citric acid ! WARNING Nitric acid is highly caustic. Citric acid can irritate the skin and eyes and cause respiratory problems. ‣ Wear protective goggles, gloves and protective clothing. ‣ Always add acids to water, not vice versa. ‣ Never attempt to swallow any of the solution prepared. Shelf life: Storable parent solutions with concentrations of 100,000 mg/l are stable for 12 months if stored in a cool, dark place at 4 to 8 °C (40 to 46 °F). Prepared standard solutions must be used within four weeks even if stored in a cool, dark place. Concentrations: depends on the application. Material: • 1-liter volumetric flask • Crtric acid monohydrate C6H8O7 · H2O (purity: p.a.) • Nitric acid HNO3 (65 %, purity: p.a.) Procedure: For an organic carbon solution with a concentration of 100,000 mg/l, dissolve 291.6 g of citric acid monohydrate in 500 ml of deionized water in a 1-liter volumetric flask (other concentrations of the solution are listed in the table below). Carefully add 55.0 ml (77.0 g) of nitric acid. Once the chemicals have dissolved, top up the mixture with water until the 1-liter mark is reached. Stir the solution once more. Label the container, indicating the contents and the date of preparation. mg/l carbon Citric acid in g Nitric acid in ml Volume 100,000 291.6 55.0 1l 50,000 145.8 55.0 1l 10,000 29.16 55.0 1l The solution with a concentration of 100,000 mg/l is stable (particularly when refrigerated). To reduce the concentrations if necessary, serial dilutions based on a standard substance of 100,000 mg/l are recommended. Example: • If 10 ml of a solution with a concentration of 100,000 mg/l is diluted with 90 ml deionized water, this results in a concentration of 10,000 mg/l. • If 10 ml of a solution with a concentration of 10,000 mg/l is diluted with 90 ml deionized water, this results in a concentration of 1,000 mg/l. • If 10 ml of a solution with a concentration of 1,000 mg/l is diluted with 90 ml deionized water, this results in a concentration of 100 mg/l. Serial dilution is the preferred method for creating lower concentrations. This is instead of diluting 1 ml of the 100,000 mg/l solution with 99 ml deionized water. The latter method can result in measurement errors. Preparing the stripping reagent Stripping reagent dosing is regulated via the pH sensor. The regulation range of the dosing is from the minimum feed rate of the acid pump to approximately 300 times this amount. The necessary acid quantity varies greatly from measuring place to measuring place. Ideally, the strength of the acid in the feeder tank should be set in such a way that the system can regulate in both directions, but the regulation range should be higher for higher volumes of acid dosed. 18 Endress+Hauser TOCII CA72TOC Installation Regulation aid: The concentration of the acid is typically in the region of 5 to 10 %. The aim should be to achieve a feed rate of 2 to 5 % (1.7 μl/min to 4.4 μl/min) for pump P3 (the current feed rate can be read in the PROGRAMMING/TEST/OUTPUT/PUMPS menu). For the acid feeder, mix 0.5 l deionized (DI) water with 0.125 l HNO3 25 % HNO3. • Fill the acid hose • Start measuring operation with a real sample • Allow the acid dosing system to regulate • Feed rate > 2 % < 5 %, note the acid concentration and use for future mixtures • Feed rate < 2 % acid concentration, dilute preparation • Feed rate > 5 % acid concentration, increase the concentration of the preparation • Replace the contents of the acid hose • Allow the acid dosing system to regulate, read off the feed rate Increase concentration Dilute Deionized water (ml) HNO3 25 % (ml) HNO3 concentration 500 + 125 5.0 % + 125 8.3 % + 125 10.7 % +125 12.5 % +125 5.0 % 500 + 500 2.8 % +1000 1.5 % +2000 0.8 % Use of other acids • Nitric acid Nitric acid does not form lyophobic salts in the strip chamber. The resulting nitrogen oxides in the combustion gas are filtered out with an acid filter upstream from the IR detector. • Phosphoric acid Phosphoric acid is a low-volatility, odorless acid that generates practically no precipitate. Following combustion, substances are formed that are filtered out completely in the heated salt trap. • Sulfuric acid Sulfuric acid is a low-volatility, odorless acid. When using sulfuric acid, precipitate can be expected with alkaline earth metal ions. In addition to the sulfur dioxides, salts are generated as a reaction product downstream from the furnace. These salts are easily removed in the heated salt trap. Gypsum can also occur if the water is very hard. • Hydrochloric acid Hydrochloric acid is a volatile acid with a pungent odor. Salts do not precipitate in the strip chamber. During combustion, salts occur (heatable salt trap) as does HCl gas, which is absorbed in the condensate. 3.3 Post-installation check • After installation, check that all connections are tightly fitted and are leak-resistant. • Check all hoses for damage. Endress+Hauser 19 Electrical connection TOCII CA72TOC 4 Electrical connection 4.1 Wiring ! WARNING Device is live Incorrect connection may result in injury or death. ‣ The electrical connection must only be carried out by a certified electrician. ‣ Technical personnel must have read and understood the instructions in this manual and must adhere to them. ‣ Prior to commencing work on the connections, ensure that no voltage is applied to any of the cables. 4.1.1 ! Preparing to wire WARNING Danger! Risk of electric shock! ‣ Disconnect the device from the power supply system (disconnect the mains plug). The line filter, the overvoltage module and the main switch are still connected to the power supply even when the main switch is switched off. ‣ Before connecting the device, make sure that the line voltage matches the voltage indicated on the nameplate. ‣ Ensure that the analyzer is sufficiently grounded via the mains connection. The analyzer is available for the following line voltages. • 115 V AC 50 Hz • 115 V AC 60 Hz • 230 V AC 50 Hz • 230 V AC 60 Hz The following condition must be met when grounding the analyzer via the mains connection: 50 V < R · Imax Imax = maximum current at which the residual current circuit breaker is not yet triggered. R = the resistance between protective ground and device ground. If this condition cannot be guaranteed, the device must be grounded on site. You must make the following connections: • Alternating current connection via mains plug • External grounding if necessary • Analog 0/4 to 20 mA outputs • Binary outputs • Binary inputs • RS-232 The signal connections are located in the EMC screening box on the right-hand side of the cabinet. The connection for the external ground is located at the bottom on the left-hand side of the cabinet. 20 Endress+Hauser TOCII CA72TOC Electrical connection 4.1.2 Power distribution a0025863 Fig. 5: Endress+Hauser Power distribution wiring diagram 21 Electrical connection TOCII CA72TOC Terminal strip assignment: Connection Description 3 Main switch, power distribution 4 Solenoid valve 3 - stripping gas 6 Peltier cooler regulator 7 Membrane compressor 8 Tube furnace 9 External salt trap 10 Solenoid valve 4, standard 1 + 2 11 Solenoid valve 7, carrier gas 13 Solenoid valve 5, bypass screen rinsing 14 Solenoid valve 1, sample/standard 15 Solenoid valve 6, channel 1/channel 2 (optional) 16 24 V power supply 17 Solenoid valve 2, strip chamber rinsing 18 Solenoid valve 8, dosing Relay module assignment: Relay No. Relay type Function 1 4A Solenoid valve 1, sample/standard 2 3A Solenoid valve 2, strip chamber rinsing 3 25A Solenoid valve 3 stripping gas, tube furnace regulator, external salt trap regulator, Peltier cooler regulator, membrane compressor 4 4A Solenoid valve 4, standard 1 + 2 5 4A Solenoid valve 5, bypass flush 6 4A Solenoid valve 6 channel 1 / 2 7 4A Solenoid valve 7, carrier gas 8 3A Solenoid valve 8, dosing RA 25A Emergency shutdown RB 25A Heating regulator furnace RC 25A Heating salt trap The power distribution is located at the back in the top door. 22 Endress+Hauser TOCII CA72TOC Electrical connection 4.1.3 Signal connection I 1 1 II 2 1 2 0/4-20 mA + 0/4-20 mA + binary in 2 III 1 IV binary out 2 40 - 41 - 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND RS 232 a0011911 Fig. 6: I II III IV 40 41 Endress+Hauser Signal connection Alert Alarm for limits Standby Operating control Signal output channel 1 Signal output channel 2 (optional) 1 2 3 4 5 6 7 8 Calibration, external activation Adjustment, external activation Screen flush, external activation Power flush, external activation Not assigned Not assigned Standby, external activation Channel switchover, external activation (optional) Messages I to IV Potential-free relay contact (max. 0.2 A and 50 V), normally closed (NC) Relay contact I closed = no fault messages Relay contact II closed = no collective alarm Relay contact III closed = standby Relay contact IV closed = operating check At the end of a measuring cycle, relay IV opens for 2 seconds to signal the end of the measuring cycle. Signal outputs 40 to 41 0 to 20 mA or 4 to 20 mA can be switched, galvanically isolated, max. load 500  Signal inputs 1 to 8 24 V DC active, max. load 500  23 Electrical connection TOCII CA72TOC Signal input Description Switch status off (open) Switch status on (closed) 1 Calibration, external activation Analyzer is in measuring mode Calibration is triggered 2 Adjustment, external activation Analyzer is in measuring mode Adjustment is triggered 3 Screen flush, external activation Analyzer is in measuring mode Screen flush is triggered 4 Power flush, external activation Analyzer is in measuring mode Power flush is triggered 5 Not assigned 6 Not assigned 7 Standby, external activation Analyzer quits standby mode and returns to measuring mode or is in measuring mode Standby is triggered. Analyzer is prepared for standby. Standby is maintained as long as the switch status is closed. 8 Channel switchover, external activation (optional) Analyzer is in measuring mode for the selected channel. Channel switch is performed. The potential-free contact must be closed for approx. 2 seconds to allow the switch status to be triggered. TOCII CA72TOC is suitable for connection to industrial power supply systems in accordance with EN 61326-1, Class A. 24 Endress+Hauser TOCII CA72TOC Electrical connection 4.1.4 Power unit 24V +- 23A 24V +24V +24V +T + - 23 21 20 22 a0011956 Fig. 7: Power unit assignment Power unit wiring arrangement: Connection Description 20 Pump control 24 V DC 21 Magnetic stirrer control 24 V DC 22 Motor 23 Relay module 24 V DC 23A Ventilator 24 V DC The connections for the power unit are located on the rear side of the computer. Endress+Hauser 25 Electrical connection TOCII CA72TOC 4.1.5 Distributor connection a0021331 Fig. 8: Distributor (* = Pin 1 at MI1 - MI4 and at PWM) Distributor assignment Connection Description FI-24 NDIR detector FI-26 pH - amplifier BI-28 Carrier gas pressure switch DI 06 BI-29 Leak detector DI 05 BI-30 Standby internal DI 04 BI-34 Peltier cooler regulator DI 01 + 02 BI-35 Pressure switch dilution water DI 03 PWM-1 Furnace regulator (pin 1 black, Pin 2 blue) PWM-2 Salt trap regulator (pin 3 brown, pin 4 gray) BO-39 Relay module Pu-38 Pump control Ext. 55 External connection socket MI1 Temperature sensor, furnace regulator, type K (pin 4 green, pin 6 white) MI2 Temperature sensor, furnace monitoring, type J (pin 4 green, pin 6 white) MI3 Temperature sensor, salt trap regulator, type J (pin 4 black, pin 6 white) MI4 Pressure sensor (pin 1 VS brown, pin 3 signal + black, pin 4 signal – gray, pin 6 GND blue) 4.1.6 26 Fuses Assembly Fuses Power distribution 2.5 A, slow-blow, design: fine-wire fuse 6.3 x 32 Relay 4 A per relay, slow-blow, design: TR5 Power unit 2 A, slow-blow, design: fine-wire fuse 5 x 20 Endress+Hauser TOCII CA72TOC Electrical connection 4.2 Post-connection check Carry out the following checks after electrical connection: Device status and specifications Note Is the exterior of the analyzer or cable undamaged? Visual inspection Electrical connection Note Does the supply voltage correspond to the data on the nameplate? 230 V AC 50/60 Hz 115 V AC 50/60 Hz Are current outputs shielded and connected? Are the mounted cables strain-relieved? Are the cable types properly separated? Run power supply and signal lines separately over the entire travel distance. Separate cable channels are ideal. Are the cables routed without loops or crossovers? Are power supply and signal lines connected correctly according to wiring diagram? Are all screw terminals tightened? Are all cable entries mounted, tightened and leak-resistant? Endress+Hauser 27 Operation TOCII CA72TOC 5 Operation 5.1 Operating elements a0011861 Fig. 9: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 28 Display and operating elements Main switch Display and operating elements USB connection Pump P2 sample analysis Junction box Compressor switch Ventilator Separation chamber Dosing valve Ventilator Injection unit Acid filter Tube furnace with catalyst Air outlet (filter pad) Combined filter (water trap) 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Heated salt trap (optional) Circuit gas flowmeter Dilution water pump P5 (optional) Acid hose connector MV4 calibration standard changeover C1/C2 MV1 wastewater/calibration standard changeover Valve for online sample/manual sample Pump P3, acid dosing Pump P4, sample - dilution (optional) Mixing chamber (optional) Pump P1, sample - strip chamber/condensate extraction Condensate hose connector Strip chamber with pH electrode Sample conditioning Endress+Hauser TOCII CA72TOC Operation 5.2 Display and keypad 1 2 3 4 5 6 7 9 8 a0007996 Fig. 10: 1 2 3 4 5 6 7 8 9 Display and operating elements Display, 16 rows a 40 characters Keyboard Arrow keys (cursors) Function key"Measuring" Function key "Service" Function key "Programming" Function key "Help" Key "Enter" "CLR" key "Operation" key Pressing the "Operation key" takes you back to the measuring mode. The display shows the measured value trend of the last six hours in graphic form. "Service" key Pressing the "Service key" takes you to the maintenance mode. The menu contains the following items: • Pumps • Calibration • Cleaning • Filter "Programming" key Once you have pressed the "Programming key" and entered the four-digit code (see code card supplied), you will be taken to the programming menu. The menu contains the following items: • Setting You can configure the measuring device here. • Lists You can visualize the reports and alarm messages on the display here. • Test You can use test programs to test the functions of the device here. Use the help key [?] to obtain additional information on the current date and the program version. Arrow keys The arrow keys help you position the cursor on the screen. The "right" arrow key allows you enter negative values for certain parameters. A minus sign appears once this key has been pressed. Endress+Hauser 29 Operation TOCII CA72TOC "Enter" key The "Enter key" has the following functions: • You launch a menu item. • You start a program item. • You always confirm an entry with the "Enter key". • When performing maintenance and service tasks, you confirm each step with the "Enter key" on completion of the step. "?" key A short help text on the program item appears when you press the "? key". Press the "? key" a second time to exit the help text. "4" key Calls up the limit value list. The current limit value violations are displayed. "5" key Calls up the fault list. The current faults and alarms are displayed. "6" key Calls up the selected automatic service. The selected service and the remaining time in seconds until the next service are displayed. "7" key On devices with two sample flows, you can use the "7" key to toggle between the values displayed on the screen for the two sample flows. "." key (period key) The period key indicates the current procedural step in measuring mode. If you press the period key again, the following data are displayed: • Temperature • pH value • Pressure in gas circuit • Feed rate of pump P3 "CLR" key You can display the following information on the screen with the "CLR key": • Device type • Software program version • Device options 30 Endress+Hauser TOCII CA72TOC Operation 5.3 Operation during measuring mode The analyzer has three operating modes: • Measuring mode • Service mode • Programming mode The measuring mode is fully automated. Manual intervention on the part of the user is not possible. 11:39:04 1000 1 500 2 6 00 5 00 7 00 8 00 IR = 334 ppm 5 9 00 10 00 11 00 234 3 TOC mg/l 4 a0012443 Fig. 11: 1 2 3 4 5 Display during measuring operation Time Load curve of the past 6 hours Timeframe Measured value Measured value of the IR detector 5.3.1 Recording mode Pressing the U key when in measuring mode takes you to recording mode. Using the arrow keys, scroll between the measured values recorded: • V 1 day earlier • W 1 day later • U 2 hours earlier • T 2 hours later Once you have selected the required period, press the Enter key. Recording time: • 14 days for one-channel operation • 7 days for two-channel operation Use the operation key to quit recording mode. Endress+Hauser 31 Operation TOCII CA72TOC 5.3.2 Spot view The spot view is activated in the recording mode by pressing the Enter key. The following information is displayed: • Load curve • Measured value • Date • Time A small cursor on the display indicates where you are currently in the load curve. 1000 1 500 5 00 6 00 RECORD DATE 08/29/08 7 00 8 00 9 00 10 00 11 00 2 VALUE= 238 mg/l TIME= 8:30 a0012449-en Fig. 12: 1 2 V W Spot view (example) Time mark on the load curve Measured value of the selected time 1 hour earlier 1 hour later U T 2 minutes earlier 2 minutes later You can switch the spot view (cursor) off with the Enter key. 32 Endress+Hauser TOCII CA72TOC Operation 5.4 Standby mode The standby mode can be used to operate the analyzer at measuring points where the flow of sample is interrupted at times. The option is available in the one-channel version with a PA-2 or PA-3 sample conditioning system. 4 3 5 2 1 a0013853 Fig. 13: 1 2 3 4 5 Standby switch Adapter fitting for the pressure monitor Pressure monitor ¼" Signal connection Protection cap Bypass screen Mode of operation If the flow of sample is interrupted, the pressure monitor reports this status to the computer via switch input DI 04. This causes the device to respond as follows: • All the pumps are stopped. • Pump P2 is drained. • The strip chamber is rinsed. • The current output is set to 0.0 mA. • The analyzer operates without displaying a measured value. The device resumes measuring operation automatically as soon as sample flows again. Endress+Hauser 33 Commissioning TOCII CA72TOC 6 Commissioning 6.1 Function check ! CAUTION Avoid damages resulting from incorrect power supply and incorrect or poorly executed hose connections. ‣ Check all connections for correctness. In particular, verify that all the hose connections are securely positioned to ensure that no leaks occur. ‣ Verify that the line voltage matches the voltage specified on the nameplate. 6.2 Start 6.2.1 Commissioning sequence Preparation: 1. Install the pH sensor in the strip chamber and connect the sensor cable to the amplifier. 2. Remove the transportation lock (cable ties) on the furnace unlocking device. 3. Place the combustion pipe insert with the catalyst into the furnace (see "Maintenance" section) and install the heated salt trap (optional). 4. Mount the hose casettes (see the "Maintenance" section). 5. Place the stripping reagent in the reagent tray beneath the measuring device, and put the standards C1 and C2 (see "Preparing the chemicals" section) in the reagent bottle holders provided on the left side panel. Starting the analyzer: 34 1. Switch on the analyzer. The furnace begins to heat up. 2. In the programming mode, configure the operating parameters of the analyzer. 3. Adjust the pH sensor (> CALIBRATION > ADJUSTMENT pH SENSOR). 4. Adjust the peristaltic pumps P1 and P4 (> PUMPS > REPLACE HOSE P1/4). 5. Adjust the peristaltic pump P2 and determine the empty volume ( > PUMPS > ADJUST P2 and > CALIBRATION > EMPTY VOLUME DOSING). 6. Once the analyzer is in operation following warm-up and the temperature is stable, check the gas circuit for leaks (> CLEANING > LEAKAGE TEST). 7. Perform a 2-point adjustment ( > CALIBRATION > ANALYZER ADJUSTMENT). Endress+Hauser TOCII CA72TOC Commissioning 6.2.2 Updating the analyzer software Regardless of the menu structure, you can update the analyzer software via the USB interface. ! WARNING Risk of electric shock due to defective device connected via USB! ‣ Use only passive USB devices. Step 1 Display Description 1. Switch off the main switch. 2. Plug the USB stick with the desired software into the USB interface. 3. Switch the main switch back on. Logo appears. 2 Press the [CLR] key. 3 Press [1] key. Keys [2] and [3] are reserved for E+H Service. [CLR] Cancel and start existing analyzer software 4 A list of all software versions available is displayed. [▴▾] Scroll up and down [◂▸] Page through (if more than 12 versions are available) [.] Select software version (* = marking) [CLR] Delete software version (! = marking) [E] Confirm Only one version can be selected for updating. Several versions can be selected for deletion. Endress+Hauser 35 Commissioning TOCII CA72TOC Step 5 Display Description [E] Confirm the selected software version and start the software. [CLR] Back to selection menu The analyzer goes into measuring mode once the software has been started. You can check the software version when in measuring mode using the [CLR] key. 6 Remove the USB stick once the software has been updated. The software versions will remain available in memory until they are deleted. For improved clarity, it can be useful to delete these software versions if further updates are carried out. 36 Endress+Hauser TOCII CA72TOC Commissioning 6.3 Programming mode You configure the operating parameters of the analyzer in the programming mode. 1. Press the programming key. 2. Enter the "code". The code is a four-digit number which you can find on the code card supplied with your analyzer. 3. Press the [E] key. The following menu appears: a0012583-en Fig. 14: "Programming" menu The operating parameters are stored in the analyzer and are retained in the event of a software update. Within the menu items, pressing the [<] key takes you back to the "Programming" menu. 6.3.1 Menu SETTING - RANGE DATA a0012553-en Fig. 15: Endress+Hauser Menu "Setting" 37 Commissioning TOCII CA72TOC Parameter Unit Factory setting Description SCALE mg TOC/l 1000 Use this function to enter the maximum concentration for your measuring point here. This value determines the scale end value for the graphic interface. Enter two independent values for the two-channel version. SCREEN FLUSH n/day 0 The number of automatic flush cycles for the bypass screen per day (recommended value: 2). DURA.SCREEN FLUSH s 15 When a screen flush is activated, the duration of the flush can be altered. If longer than 15 seconds, two thirds of the flush time is assigned to flushing the screen and one third to flushing the strip chamber. POWER FLUSH n/day 0 The number of automatic power flush cycles for the stripping vessel and separation chamber per day (recommended value: 2). PAUSE CYCLE s 0 Interval between 2 measurements. P1 (B) ml/min 7.5 Feed rate of pump P1. P2 (B) μl/min 250 Feed rate of pump P2. P4 (B) ml/min 5.0 Feed rate of pump P4 (optional). The feed rates of pumps P4 and P5 determine the dilution ratio. P5 (B) ml/min 25.0 Feed rate of pump P5 (optional). The feed rates of pumps P4 and P5 determine the dilution ratio. VOL.BATCH μl 300 Dosing volume for a batch. Increasing the volume increases the sensitivity of the measuring system but also increases the salt load. STANDARD C1 mg/l 80 Concentration of standard solution C1. STANDARD C2 mg/l 720 Concentration of standard solution C2. CAL./ADJUST. n days 3 Here you can specify after how many days a calibration or adjustment should be performed. The automatic function is switched off with the value 0. CAL./ADJUSTMENT TIME xx.xx 23.00 Here you can specify the start time for the calibration or adjustment. Enter as a decimal number. Example: 22.50 corresponds to 22:30 hrs. 2 Use this function to specify which function should be executed. CAL/ADJUSTMENT • 1 - Calibration • 2 - Adjustment The function is executed 90 minutes before the day changes. 38 Endress+Hauser TOCII CA72TOC Commissioning 6.3.2 Menu SETTING - BASIC DATA a0012580-en Fig. 16: "Programming" menu Parameter Unit Factory setting Description DC OUT mA 4 Sets the signal output to 0 to 20 mA or 4 to 20 mA. SCALE AO mg/l 1000 Scale end value of the analog output. e.g. 1000 mg/l = 20 mA EMPTY VOLUME P2 * μl 220 Dead volume of pump P2 from the separation chamber to the end of the capillary. P1 100% * ml/min 5.6 Feed rate of pump P1 at 100 % pump capacity. P2 100% * μl/min 870 Feed rate of pump P2 at 100 % pump capacity. P3 100% μl/min 870 Feed rate of pump P3 at 100 % pump capacity. P4 100% * ml/min 5.6 Feed rate of pump P4 at 100 % pump capacity (optional). P5 100% * ml/min 30 Feed rate of pump P5 at 100 % pump capacity (optional). ADJUSTMENT CONSTANTS Do not change this value! X0 * 0.0 Offset, value is overwritten during adjustment KP * 50 Slope, value is overwritten during adjustment PH-CONTROL 1.00 The measuring device is equipped with automatic pH control in the stripping vessel. You can use this parameter to switch pH control on or off. • 1.00 = pH control is switched on Reading on display = TOC • 0.00 = pH control is switched off Reading on display = TC Endress+Hauser PH-NOMINAL 2.5 The pH value in the stripping vessel is set here. The pH value must be between 1 and 4 for complete stripping. If the sample becomes excessively acidic in municipal sewage treatment plants, there is the problem of humic acid precipitating which could mask the carbonate. This inorganic carbon enters the furnace and results in excessively high readings. PH ADJ.OFFSET * 2.4 Offset of the pH sensor. The value is overwritten when the pH sensor is adjusted. 39 Commissioning TOCII CA72TOC Parameter Unit Factory setting Description PH ADJ.SLOPE * mV/ decade 57.5 Slope of the pH sensor. The value is overwritten when the pH sensor is adjusted. * These parameters are adapted by means of menu-guided adjustments. 6.3.3 Menu SETTING - ALARM LIMITS Use this function to enter the limit values for the high alarm and low alarm. a0012579-en Fig. 17: 40 "Programming" menu Parameter Unit Factory setting Description HIGH ALARM LIMIT mg/l 12000 Use this function to specify the alarm value for when the value is overshot. LOW ALARM LIMIT mg/l 0 Use this function to specify the alarm value for when the value is undershot. Endress+Hauser TOCII CA72TOC Commissioning 6.3.4 Menu SETTING - SET CLOCK This section describes how you enter the date and the time. Select the programming mode for this purpose. Step Display Description 1 2 [] increases value by 1. [] reduces value by 1. [] to go to previous value [] to go to next value [E] confirms the displayed value. 3 6.3.5 Step Menu SETTING - SET BRIGHTN./CONTR. Display Description 1 2 Endress+Hauser [E] confirms the displayed value. [] and [] switch between brightness and contrast. [] increases value by 1. Use [] reduces value by 1. Range: 0 to 100 % 41 Commissioning TOCII CA72TOC 6.3.6 Menu SETTING - MEASURING SITE You can give the measuring point a name. a0012582-en Fig. 18: "Programming" menu In the factory setting, the name is MEASURING SITE. • Select the position of the character using the cursor buttons T and U. • Select the character using the V and W cursor buttons. • Pressing the "1" key switches the character to "A". 6.3.7 Menu LISTS - SHOW COMPLETE RECORDS a0012588-en Fig. 19: "Lists" menu Chronological display of all the events saved. The last 200 events are saved in the complete record list. XX.XX XX.XX Date XX:XX XX:XX Time XXXXXXXXXXXXX XXXXXXXXXXXXX Event a0012593-en Fig. 20: 42 Complete records Endress+Hauser TOCII CA72TOC Commissioning 6.3.8 Menu LISTS - ALARM RECORD a0012587-en Fig. 21: "Lists" menu All the alarm messages, including the date and time of the event, are logged in the alarm record. ALARM RECORD Date XX.XX XX.XX Time XX:XX XX:XX Event on/off XXXXXXXXXXXXX XXX XXXXXXXXXXXXX XXX a0012592-en Fig. 22: Endress+Hauser Alarm record Alarm Description ALARM TMEASURING RANGE The value is outside the measuring range The IR detector has been working above its maximum value for over 10 minutes or the measuring device has been measuring 0 mg/l for over an hour. MALFUNCTION IR IR detector is defective Operation stops. The analyzer restarts automatically once the error status is reset. LEAKAGE Leak in the system The furnace and carrier gas supply will be switched off. The analyzer must be started manually. 43 Commissioning 44 TOCII CA72TOC Alarm Description ADJUSTMENT ERROR Adjustment error An error number is assigned to the error. UNSTABLE DOSING Error when dosing the sample The minimum number of drops to be expected was undershot. WATER PRESS. FAILURE Failure in the supply of water for flushing and dilution The pressure is below the minimum permitted pressure of approx. 1.5 bar (21 psi). Operation stops. The analyzer restarts automatically once the error status is reset. CHECK CO2 BASIC LINE The CO2 threshold value (ppm) or the CO2 drift (ppm/min) was overshot in basic line measurement INPUT ERROR C1>C2 Error during entry of standard concentrations. The concentration of standard C1 must be lower than the concentration of standard C2. CIRCUIT PRESSURE HIGH At 175 mbar, the pressure in the gas circuit is 70 % above the pressure permitted in the gas circuit (250 mbar). CIRCUIT PRES.TOO HIGH The maximum permitted pressure in the gas circuit has been exceeded. The max. set value for pressure is 250 mbar. INTERNAL COM-FAULT Fault in internal communication between I/O card, keyboard and modbus connection. Operation stops. The analyzer restarts automatically once the error status is reset. Endress+Hauser TOCII CA72TOC Commissioning 6.3.9 Menu LISTS - MAINTENANCE RECORD a0012586-en Fig. 23: "Lists" menu All the maintenance procedures are recorded by maintenance activity in the maintenance record. Maintenance procedures that have not been carried out cannot be selected. Endress+Hauser Action Description PROGRAM STARTED Date and time when program starts CHANGE DATA Date and time of when the setting data are changed CHANGE TIME Date and time when clock changes The newly set time and the time difference in hours compared to the old time are documented. Negative value: The clock was put back. Positive value: The clock was put forward. ADJUSTMENT Date and time of when the analyzer and the CO2 concentrations of the standard solutions are adjusted Value 1: CO2 concentration of C1 [ppm] Value 2: CO2 concentration of C2 [ppm] ADJUSTMENT CONSTANTS Date and time and the adjustment constants obtained during adjustment Value 1: Offset [ppm] Value 2: Standardized slope [ppm] CALIBRATION Date and time of the calibration of the analyzer and the TOC value found, and the recovery with regard to the specified concentration of standard C2 Value 1: TOC [mg/l] Value 2: Recovery [%] BASIC LINE DRIFT Date and time of the basic line drift when calibrating and adjusting Value 1: Basic line offset [ppm] Value 2: Basic line drift slope [ppm/min] EMPTY VOLUME DOSING Date and time when selected in the service menu Value 1: Duration of the filling process [s] Value 2: Volume [μl] ADJUSTMENT PUMP P1 Date and time of when pump P1 is adjusted Value 1: new feed rate (ml/min) Value 2: old feed rate (ml/min) ADJUSTMENT PUMP P2 Date and time of when pump P2 is adjusted Value 1: new feed rate (μl/min) Value 2: old feed rate (μl/min) ADJUSTMENT PUMP P4 Date and time of when pump P4 is adjusted Value 1: new feed rate (ml/min) Value 2: old feed rate (ml/min) 45 Commissioning 46 TOCII CA72TOC Action Description ADJUSTMENT PH-SENSOR Date and time and the adjustment constants obtained during adjustment Value 1: Offset [mV] Value 2: Slope [mV/log pH] REPLACE HOSE P1 Date and time of when the hose of pump P1 is changed REPLACE HOSE P2 Date and time of when the hose of pump P2 is changed REPLACE HOSE P3 Date and time of when the hose of pump P3 is changed REPLACE HOSE P4 Date and time when the hose of pump P4 is changed when sample predilution is present SCREEN FLUSH Date and time when selected in the service menu Automatic screen flushing is not logged. BYPASS SCREEN Date and time when selected in the service menu POWER FLUSH Date and time when selected in the service menu Automatic power flushing is not logged. STRIPPING+SEPARATION Date and time when selected in the service menu OPEN GAS CIRCUIT Date and time when selected in the service menu COMBUSTION PIPE Date and time when selected in the service menu LEAKAGE TEST Date and time when exiting the leak tightness display Value 1: Current pressure Value 2: Current leakage rate [mbar/min] Typical value: -0.5 to -2.0 mbar/min REPLACE ACID FILTER Date and time when selected in the service menu REPLACE GAS FILTERS Date and time when selected in the service menu HEATED FILTER Date and time when selected in the service menu (heated salt trap) REPLACE O2 FILTER Date and time when selected in the service menu STANDBY Date and time of a standby event SAVE DEFAULTS Date and time when selected in the Setting menu SET DEFAULTS Date and time when selected in the Setting menu Endress+Hauser TOCII CA72TOC Commissioning 6.3.10 Menu LISTS - MIN MAX AVERAGE a0012585-en Fig. 24: "Lists" menu This menu item displays the maximum, minimum and average measured values for the days saved. 6.3.11 Menu LISTS - RECORD ALL DATA This menu item is used to save the measuring data and protocols from the last 14 days. The data records are available as csv files. Step Display Description 1 2 RECORD DATA 01 02 03 04 05 06 07 - 06.02.2013 05.02.2013 04.02.2013 03.02.2013 02.02.2013 01.02.2013 31.01.2013 [E] TO END 3 Endress+Hauser 08 09 10 11 12 13 - 30.01.2013 29.01.2013 28.01.2013 27.01.2013 26.01.2013 25.01.2013 If the time or the date are changed within these 14 days, the data will be re-dated accordingly. If the date change is outside of these 14 days, the memory will be completely deleted. [1] SAVE Connect the storage medium to the USB connection. 47 Commissioning TOCII CA72TOC Step 4 Display Description RECORD DATA 01 02 03 04 05 06 07 - 06.02.2013 05.02.2013 04.02.2013 03.02.2013 02.02.2013 01.02.2013 31.01.2013 08 09 10 11 12 13 SAVE DATA, PLEASE WAIT 5 USB CAN NOW BE REMOVED - 30.01.2013 29.01.2013 28.01.2013 27.01.2013 26.01.2013 25.01.2013 01:55 Always remove the storage medium! [E] TO END 48 Endress+Hauser TOCII CA72TOC Commissioning 6.3.12 Step Menu TEST - INPUT TEST Display Description 1 1. Select the desired inputs. 2. Press the [E] key. 2 Analog inputs Current CO2 measured value • T1 = Temperature furnace monitoring • T2 = Temperature heating regulation furnace, PWM performance display • T3 = Temperature heating regulation salt trap, PWM performance display • pH value in stripping vessel • Pressure level in gas circuit Switch inputs Switching status of the switch inputs Ix = 0 = OFF Ix > 0 = ON IN1= Peltier cooler, Peltier regulator BI34 IN2= Peltier cooler, Peltier regulator IN3= Dilution water BI35 IN4= Standby no. BI30 IN5= Leak detector no. BI29 IN6= Carrier gas pressure switch BI28 Endress+Hauser 49 Commissioning TOCII CA72TOC 6.3.13 Step Menu TEST - OUTPUT TEST Display Description 1 1. Select the desired outputs. 2. Press the [E] key. 2 3 MEAUSREMENT OFF deactivates measuring mode. The MEASUREMENT OFF operating status is displayed. Select this status to test the inputs without triggering an alarm. TEST DC-SIGNAL CHANNEL NO. 1 CHANNEL NO. 2 4 Pumps Parameter for testing the function of the pumps Negative value turns the direction of flow. 5 Switch outputs Displays the switching status of the switch outputs (see the following table). ON/OFF using Enter key 6 TEST COM ... [E] TO END 50 0.0 mA 0.0 mA Current output Sets the analog current outputs to any value between 0 and 20 mA. TEST COM displays the transmission data for the computer interface RS 232. The menu item allows users to test the transmission of data with an external terminal. Once the data connection is established, a data string is transmitted every 2 seconds. Keystrokes at the external terminal are shown on the display. Entries at the terminal must be transmitted using a carriage return. Endress+Hauser TOCII CA72TOC Commissioning Output Description Switch status OFF (contacts opened) Switch status ON (contacts closed) SA1 Changeover between standard and sample Sample Standard solution SA2 Flushing valve for power flushing Strip chamber flushing switched off Strip chamber flushing switched on SA3 Carrier gas supply, tube furnace regulator, Peltier cooler regulator, membrane compressor Consumer load switched off Switch status during measuring operation SA4 Changeover between standard 1 and standard 2 Standard 1 Standard 2 SA5 Screen flushing valve Screen flushing valve off Screen flushing valve on SA6 Optional: Changeover between channel 1 and channel 2 Channel 1 Channel 2 SA7 Carrier gas flushing valve Carrier gas flushing off Carrier gas flushing on SA8 Dosing valve Dosing valve open Dosing valve closed SA9 Collective alarm fault relay I (e.g. failure acid, leak) Fault on Fault off SA10 Collective alarm limit values relay II Limit value alarm on Limit value alarm off SA11 Standby relay III Standby off Standby on SA12 Operation check relay IV At the end of the measuring cycle in measuring mode, the contact is opened for 2 sec to signal the end of the measuring cycle. If the analyzer is in service mode or in a fault state in which TOC measurement is not permitted, the contact is opened. During operation, the contact is closed as soon as the displayed measured value is reliable (e.g. following a service, this contact is closed once the first TOC measured value has been determined). 6.3.14 Two-channel: external changeover The analyzer is equipped with one or two separate sample supply systems. The current sample selected is controlled externally by signal input 8 (binary in 8). Signal input 8 = 0 channel 1 Signal input 8 = 1 channel 2 If the analyzer is operated with one sample conditioning system, the operator must ensure that the right sample is at the bypass when a channel switch is requested. If the analyzer is operated with two sample conditioning systems, the solenoid valve MV6 is used internally to switch the channels. If the signal status at signal input 8 changes, the measuring cycle is terminated immediately and the system immediately commences channel switchover. If the "Operation" key is pressed during channel switchover, the process of switching channels is aborted and the measuring cycle commences in the active channel. Conditioning of the analyzer to the sample in the active channel is suppressed. The measuring channel cannot be switched manually. Endress+Hauser 51 Commissioning TOCII CA72TOC Settings for the graphic interface You must enter the following parameters in the Range Data menu: PROGRAMMING/SETTING/RANGE DATA: Parameter Unit Description SCALE CH1 mg TOC/l Use this function to enter the maximum concentration for channel 1 here. This value determines the scale end value for the graphic interface. SCALE CH2 mg TOC/l Use this function to enter the maximum concentration for channel 2 here. This value determines the scale end value for the graphic interface. Settings for the analog outputs You must enter the following parameters in the Basic Data menu: PROGRAMMING/SETTING/BASIC DATA: Parameter Unit Description SCALE AO CH1 Scale end value of the analog output of channel 1. SCALE AO CH2 Scale end value of the analog output of channel 2. Settings for the alarm limits You must enter the following parameters in the ALARM LIMITS menu: PROGRAMMING/SETTING/ALARM LIMITS: Parameter Unit Description HI ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value for channel 1 is overshot. LO ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value for channel 1 is undershot. HI ALARM LIMIT CH2 mg/l Use this function to specify the alarm value for when the value for channel 2 is overshot. LO ALARM LIMIT CH2 mg/l Use this function to specify the alarm value for when the value for channel 2 is undershot. All the alarm limits affect the same signal output II (binary out II). A limit value alarm is also retained following channel switchover until the limit value for the channel in question is undershot. 52 Endress+Hauser TOCII CA72TOC Commissioning 6.3.15 Two-channel: time-controlled changeover The analyzer is equipped with two separate sample supply systems. Configuring the measuring duration The measuring duration can be individually configured for each channel. PROGRAMMING/SETTING/BASIC DATA: Parameter Unit Description DURATION CH1 min Measuring duration for channel 1 DURATION CH2 min Measuring duration for channel 2 If you configure a duration of 0 minutes in one channel, measurement will be performed permanently in the other channel. You have to set a duration greater than 0 minutes for at least one channel. Regardless of the measuring duration configured, any measuring cycle that has started will always be completed before the system switches to the other channel. In the case of an external switchover, the other channel is switched over to immediately. Settings for the graphic interface Using key 7 you can switch over to the graphic screen for the channel which was not selected. You must enter the following parameters in the Range Data menu: PROGRAMMING/SETTING/RANGE DATA: Parameter Unit Description SCALE CH1 mg TOC/l Use this function to enter the maximum concentration for channel 1 here. This value determines the scale end value for the graphic interface. SCALE CH2 mg TOC/l Use this function to enter the maximum concentration for channel 2 here. This value determines the scale end value for the graphic interface. Settings for the analog outputs You must enter the following parameters in the Basic Data menu: PROGRAMMING/SETTING/BASIC DATA: Parameter Endress+Hauser Unit Description SCALE AO CH1 Scale end value of the analog output of channel 1. SCALE AO CH2 Scale end value of the analog output of channel 2. 53 Commissioning TOCII CA72TOC Settings for the alarm limits You can enter the following parameters in the ALARM LIMITS menu: PROGRAMMING/SETTING/ALARM LIMITS: Parameter Unit Description HI ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value for channel 1 is overshot. LO ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value for channel 1 is undershot. HI ALARM LIMIT CH2 mg/l Use this function to specify the alarm value for when the value for channel 2 is overshot. LO ALARM LIMIT CH2 mg/l Use this function to specify the alarm value for when the value for channel 2 is undershot. All the alarm limits affect the same signal output II (binary out II). A limit value alarm is also retained following channel switchover until the limit value for the channel in question is undershot. Interrupting the time control system Regardless of the internal time-based control system, the channel can be changed manually, or by remote control via the external signal input 8 (binary in 8). Using keys 1 and 2 users can manually change to the other channel during measuring operation. Channel changeover can be triggered remotely using signal input 8. Signal input 8 = 0 has no effect Signal input 8 = 1 (for approx. 10 seconds) changes over to another channel If you trigger channel changeover by using the keyboard or the signal input, the measuring cycle is terminated immediately and the channel changeover initiated. 54 Endress+Hauser TOCII CA72TOC Commissioning 6.4 Optimizing the analyzer 6.4.1 Adjusting the measuring range Depending on its configuration, the analyzer can measure from just a few mg/l to several 10 000 mg/l. The analyzer can be optimized by changing components and altering the device settings. The measuring range is altered by changing a component: • By changing the infrared detector (Endress+Hauser Service) • By fitting a predilution system (Endress+Hauser Service) In terms of device settings, the feed rate of dosing pump P2 is optimized. Please note that optimizing the sensitivity or the salt load compatibility often demands conflicting settings on the analyzer. Select the settings the offer the best compromise for your measuring task. 6.4.2 Influence of dosing volume (pump P2) on the measuring signal The dosing range of adjustment is affected by: • Dosing volume BATCH VOL. (100 to 1200 μl) You can change the pump setting in the programming mode: SETTING - RANGE DATA. An increase in dosing volume (P2) increases the measuring signal, with a 50 % increase in the feed rate being equivalent to an approx. 50 % increase in the signal. The dosing volume of 400 μl/batch results in a sensitivity of 2 ppm CO2 per mg/l TOC (dosing volume 100 to 1200 μl/batch is equivalent to 0.5 to 6 ppm CO2 per mg/l TOC). Please note that if the sample flow is increased, the salt load also increases to the same extent. The maximum measuring range indicated on the nameplate is the range at a dosing volume of 100 μl/batch and 1200 μl/batch. Measuring range Dosing Set measuring range 0.25 to 600 mg TOC/l 100 μl/batch 300 μl/batch 1200 μl/batch 3 to 600 mg/l 1 to 200 mg/l 0.25 to 50 mg/l 1 to 2400 mg TOC/l 100 μl/batch 300 μl/batch 1200 μl/batch 12 to 2400 mg/l 4 to 800 mg/l 1 to 200 mg/l 2.5 to 6000 mg TOC/l 100 μl/batch 300 μl/batch 1200 μl/batch 20 to 6000 mg/l 8 to 2400 mg/l 2.5 to 500 mg/l 5 to 12000 mg TOC/l 100 μl/batch 300 μl/batch 1200 μl/batch 60 to 12000 mg/l 24 to 4800 mg/l 5 to 1000 mg/l Factory setting: Version A and B: 300 μl/batch Version C and D: 250 μl/batch Endress+Hauser 55 Commissioning TOCII CA72TOC 6.4.3 Operating the analyzer with high salt loads Completely diverse salt loads can occur given the different range of applications of the analyzer. For the user, this can mean that the salt load reduction function has to be optimized. The dosing pump P2 can be used to reduce the dosing volume and therefore the salt load. To reduce the salt load, it is also possible to program a break in measurement. For very high salt loads, an optional dilution module is available. Dilution ratios between 1:5 to 1:20 are possible. The effective TOC concentration in the diluted wastewater should be inside the measuring range of the analyzer. 56 Endress+Hauser TOCII CA72TOC Commissioning 6.5 Communication The analyzer is equipped with an RS-232 serial interface. Data transmission is unidirectional and is performed with the following parameters: Baud rate 9600 baud Bits 8 bit Parity N Stop bit 1 bit Handshake No The string is 104 bytes long and is sent every 2 seconds. Endress+Hauser Byte Description 0 Start byte 1 0 = Operation disabled 1 = Operation enabled 2 0 = Emergency shutdown 1 = Channel 1 measuring operation enabled 2 = Adjustment or calibration 3 = Service 4 = Programming 5 = Channel 2 measuring operation enabled 3 Leakage (0 = off, 1 = on) 4 Temperature too high (0 = off, 1 = on) 5 Low carrier gas supply (0 = off, 1 = on) 6 IR detector fault (0 = off, 1 = on) 7 Temperature too low (< 85 % Tset) (0 = off, 1 = on) 8 Outside the measuring range (0 = off, 1 = on) 9 Temperature deviation of Peltier cooler (Tset ± 3 °C) (0 = off, 1 = on) 10 pH alarm (0 = off, 1 = on) 11 Temperature deviation (< Tset -30 °C) (0 = off, 1 = on) 12 Standby (0 = off, 1 = on) 13 Limit value exceeded (0 = off, 1 = on) 14 Limit value undershot (0 = off, 1 = on) 15 Slope alarm (0 = off, 1 = on) 16 Unstable dosing, sample failure (furnace) (0 = off, 1 = on) 17 Water supply failure (0 = off, 1 = on) 57 Commissioning 58 TOCII CA72TOC Byte Description 18 Gas circuit pressure monitoring 0 = OK 1 = 70 % of max. permitted pressure 2 = > max. permitted pressure 19 Check CO2 basic line (0 = off, 1 = on) 20 Adjustment error (0 = off, 1 = on) 21 Empty (unused byte) 22 Empty (unused byte) 23 0 = No valid measured value available 1 = Valid measured value available 2 = New measured value determined (displayed for approx. 4 seconds) 24 Separator 25 0 = Sample 1 = Standard is dosed 26 Flushing strip and separation chamber with supply water 27 0 = Error shutdown active, no power is supplied to any of the units powered by the power relay 1 = Power supply active 28 0 = Standard C1 is dosed 1 = Standard C2 is dosed If relay 1 (byte 25) is set to 1 29 Flushing sample conditioning 30 Only important for two-channel operation 0 = Sample is taken from sample channel 1 1 = Sample is taken from sample channel 2 31 Flushing with carrier gas 32 A 0-1-0 change indicates that the process of dosing the sample into the furnace has been completed. 33 Separator 34 ... 39 TOC measured value (mg/l) 1 decimal place for measuring range A and B 0 decimal places for measuring range C and D 40 Separator 41 ... 46 Only for channel 2 TOC measured value (mg/l) 1 decimal place for measuring range A and B 0 decimal places for measuring range C and D Endress+Hauser TOCII CA72TOC Endress+Hauser Commissioning Byte Description 47 Separator 48 ... 53 CO2 (ppm) 1 decimal place; current value of the gas card 54 Separator 55 ... 60 CO2 (ppm) 1 decimal place; CO2 difference calculated from the measuring cycle 61 Separator 62 ... 67 pH value 2 decimal places 68 Separator 69 ... 74 Number of drops dosed into furnace No decimal places 75 Separator 76 ... 81 Batch status 82 Separator 83 ... 92 Date DD.MM.YYYY 93 Separator 94 ... 101 Time HH:MM:SS 102 Carriage return 103 Line feed 104 End of transmission 59 Diagnostics and troubleshooting TOCII CA72TOC 7 Diagnostics and troubleshooting The analyzer permanently monitors its functions automatically. Any errors detected by the device are shown on the display. ! WARNING The device is energized. Troubleshooting that is not performed correctly may result in injury or death. ‣ Troubleshooting work on the components behind the mounting plate may only be carried out by an electrical technician. ! CAUTION There is a risk of infection when working with wastewater, and there is a risk of injury when working with reagents. ‣ Wear acid-resistant protective gloves, protective goggles and a laboratory coat! 7.1 Error messages Message Cause Tests or remedial action Temperature too high The temperature at the tube furnace is 70 °C above the set point. • Select INPUT TEST. The temperatures are displayed. If there is a significant variation in the temperatures, check the temperature sensor. • It is possible that the furnace will be permanently heated. Remove the PWM connection (cable 54). If the temperature continues to rise, check relay RB. • Select INPUT TEST. If the PWM control system continuously outputs 200 %, there is a malfunction in the PWM Switch the main switch off and on - if the error persists, replace the I/O card. Possible defect: Temperature sensor, relay RB, PWM1, I/O card Temperature too low The temperature is 15 % below the set point. When putting back into operation, or during service or maintenance Possible defect: Cable, temperature sensor, relay RB, PWM1, I/O card Temperature below xxx °C • Select INPUT TEST. The temperature are displayed. If the temperature increases in INPUT TEST, wait until the warmup stage has stabilized. If there is a significant variation in the temperatures, check the temperature sensor. Verify that the temperature sensors are secured and positioned correctly on the furnace pipe. Are the contacts on the furnace connection socket and the I/O card correctly connected. • It is possible that the furnace will not be heated. Check the relay RB. • Select INPUT TEST. If the PWM control system does not regulate and continuously outputs 200 % or 0 %, there is a malfunction in the PWM. Switch the main switch off and on if the error persists, replace the I/O card. The measured temperature is 30 °C below the set temperature. When putting back into operation, or during service or maintenance Possible defect: Temperature sensor, relay RB, PWM1, I/O card 60 Endress+Hauser TOCII CA72TOC Diagnostics and troubleshooting Message Cause Tests or remedial action Carrier gas failure The pressure sensor for monitoring the carrier gas has been triggered. Pressure < 1.5 bar. Failure of carrier gas supply • Monitor the carrier gas supply. • Check signal processing (I/O card slot no. 28, switch input DI06) Go to the programming module PRG/TEST/INPUTS/SWITCH INPUTS. Release the connecting cable on the pressure switch and short-circuit the contacts. The switch state of DI06 should react on the display. If it does, replace the pressure switch. If it does not, use a multimeter to check that there are no interruptions in the cable. Replace the I/O card if the cable is OK. Possible defect: Pressure sensor, cable or I/O card Leakage The leak detector has been triggered. Leaks in the measuring device if the springs of the leak detector have been bridged. Possible defect: Leak detector, cable, I/O card Malfunction Peltier The Peltier cooler deviates > 3 °C from the set point. Following servicing or maintenance, in the event of high ambient temperatures, in the event of unfavorable suction conditions of the ventilator Possible defect: Ventilator failure, cable defective, power supply outage IR detector malfunction The measuring signal of the IR detector has failed. f < 10000 Hz After a brief power outage. Possible defect: Cable, I/O card, IR detector Endress+Hauser • Check for leaks. • Check the leak alarm for an electrical short-circuit of the spring contacts. • Check signal processing (I/O card slot no. 29, switch input DI05) Go to the programming module PRG/TEST/INPUTS/SWITCH INPUTS. Plug the cable for the carrier gas pressure switch into slot 29. The display should change at switch input DI05 when the connecting contacts on the pressure switch are bridged manually. If so, replace the leak detector. If not, replace the I/O card. Green LED on → Peltier cooler at operating temperature. Red > °C LED on → Peltier cooler is too warm. Red < °C LED on → Peltier cooler is too cold, control system is defective. • If no LED is lit, check the power supply of the Peltier cooler control system. • If the green LED is on, check the transmission cable to the I/O card and the I/O card itself. Replace the I/O card if the cable is OK. • If the red LED > °C is on, check the function of the ventilator on the cooler. Can the ventilator not draw in a sufficient amount of air? Is the air temperature too high? • Is the red LED < °C on? Peltier cooler is too cold, control system is defective, replace the Peltier cooler control system. The IR detector switches to an automatic warm-up phase following a power outage. The IR detector does not supply any power during this time. The phase is finished after approx. 30 s and the analyzer switches automatically to the measuring mode. • In the event of an error (malfunction constantly present after 60 s). • Check the connecting cable between the I/O card and the IR detector. • Replace the cable of the gas card with another cable (e.g. pH amplifier to the I/O card and check the signal input. Go to the programming module PRG/TEST/INPUTS/ANALOG INPUTS (I/O card slot No. 24 FI2 frequency input). • Replace the IR detector if the I/O card is OK. 61 Diagnostics and troubleshooting TOCII CA72TOC Message Cause Tests or remedial action Acid failure If the pH value permanently deviates more than ±2.5 from the set point. Severely fluctuating buffer capacity values • Check the acid cistern • Is the acid concentration sufficient? Does the acid pump operate at a maximum feed rate of 200 %? Increase the acid concentration in the feeder. • Is acid being dosed? In the program module PRG/TEST/OUTPUTS/PUMPS, test pump P3 by specifying values manually. Check the pump hose for leaks. • Adjust the pH sensor. • Check signal processing (I/O card slot No. 26 frequency input FI4): Disconnect the modular jack on the I/O card slot No. 26 - does the measured value drop? Replace the I/O card if there is no change in the display value. Possible defect: Cable interruption, pump hose, leaks, pump control, pH measurement Unstable dosing The drop monitor does not count any, or too few drop events • Is sample in the separation chamber? • Is pump P2 pumping medium? Can dripping be observed at the dosing head? • Is the pressure sensor OK? Go to the programming module PRG/TEST/INPUTS/ANALOG INPUTS and observe the pressure sequence when medium drips. Can a pressure increase > 10 mbar be observed? Is the furnace fitted with the combustion pipe insert? • Check signal processing: Remove the connector at MI4 (cable 53) and plug it back in. If the display has frozen, there is a malfunction in the I/O card. Switch off the main switch, wait a few seconds and switch it back on. If the error persists, replace the I/O card. Failure of water pressure The pressure sensor for monitoring the water supply has been triggered. Water pressure < 1 bar • Check the water supply. • Check signal processing (I/O card slot no. 35 switch input DI03): Go to the programming module PRG/TEST/INPUTS/SWITCH INPUTS. Release the connecting cable on the pressure switch and short-circuit the contacts. The switch state of DI03 should react on the display. If it does, replace the pressure switch. If it does not, use a multimeter to check that there are no interruptions in the cable. Replace the I/O card if the cable is OK. Possible defect: Pressure monitor, cable, I/O card Gas circuit pressure high The pressure sensor measures a high pressure in the gas circuit. A blockage is forming in the gas circuit. Possible defect: Pressure sensor, cable, I/O card Gas circuit pressure too high The pressure sensor measures too high a pressure in the gas circuit. A blockage has formed in the gas circuit. • Check the gas circuit for blockages. In particular, check the acid filter, water trap, reactor and, if necessary, the heated salt trap. Has the gas circuit flow rate fallen below 0.7 l/min? Eliminate the blockage. • Is the pressure sensor OK? Go to the programming module PRG/TEST/INPUTS/ANALOG INPUTS and observe the pressure sequence. Increase the pressure by manually squeezing the gas circuit hose for dosing. Can a pressure increase be observed? • Check signal processing: Is the plug correctly inserted in the multi in (MI) on the I/O card? Remove connection MI4 (cable 53) and plug it back in again. If the display has frozen, there is a malfunction in the I/O card. Switch the main switch off and on - if the error persists, replace the I/O card. Possible defect: Pressure sensor, cable, I/O card 62 Endress+Hauser TOCII CA72TOC Diagnostics and troubleshooting Message Cause Tests or remedial action Measured value > measuring range The IR detector continuously returns a signal that is greater than the specification. • The measured values in the flow of sample are constantly higher than the measuring device configuration. • When option pre-dilution is installed: Stop of dilution function. Faulty adjustment (adjustment error 1) CO2 concentrations • Is the gas circuit leak-tight? Check the gas-tightness of the analyzer. • Replace the standard solutions. Repeat the adjustment. measured for standard C1 or C2 are above the measuring range for the IR detector. Incorrect standard solution Possible defect: Gas circuit leaking Faulty adjustment (adjustment error 2) Calculated X0 value is above the maximum value permitted for the IR detector used. Gas circuit leaking, standard solutions Endress+Hauser • Is the gas circuit leak-tight? Check the gas-tightness of the analyzer. • Check the adjustment values in the maintenance record. Do one of the two record values deviate from the typical value? • Replace the standard solutions. Faulty adjustment (adjustment error 3) The calibration line slope is negative or zero. CO2 concentration measured for standard 1 is higher than that for standard 2 MV1, MV4, standard solutions, container empty • Verify that the solenoid valves MV1 and MV4 are functioning correctly. In the program module PRG/TEST/OUTPUTS/BINARY OUTPUTS, confirm the output SA1 for MV1 and SA4 for MV4. If the solenoid valves do not switch, replace the relevant solenoid valve. • Have the standard solutions been prepared properly? • Do the two standard solutions have the same concentration? • Have the standard solutions been swapped? • Are the standard canisters empty? Faulty adjustment (adjustment error 4) KP value is smaller than 30 or greater than 150 Gas circuit leaking, standard solutions • Is the gas circuit leak-tight? Check the gas-tightness of the analyzer. • Have the standard solutions been prepared properly? Replace the standard solutions. • Biological growth in the standard canisters. Replace the canisters. • Dilution option - feed rate of pump P4 deviates from the values determined. Use the program module SERVICE/ PUMPS/P1/P4 Replace pump hose to determine the feed rate for pump P4. Faulty adjustment (adjustment error 5) CO2 concentration < min. permitted CO2 value. (~ -9.4 % gas card measuring range) • Is the IR detector OK? Convey pure supply gas through the IR detector. Go to the programming module PRG/TEST/INPUTS/ANALOG INPUTS and check whether the IR detector displays a negative offset. Replace the IR detector if the frequency displayed has dropped below 10000 Hz. 63 Diagnostics and troubleshooting TOCII CA72TOC Message Cause Tests or remedial action Fault CO2 base- Baseline value 5 % of IR detector full scale value New catalyst, pellets for soda-lime scrubbers are used up, gas generator malfunction, defective carrier gas valve, leak in gas circuit, pump adjustment for pump P2 is no longer upto-date • Once the catalyst has been replaced, the catalyst may outgas. This can result in an error message, particularly in low CO2measuring ranges. The fault resolves itself after a few measuring cycles. • Are the pellets completely discolored? Replace the pellet filling. • Verify that the gas generator is functioning correctly. • Does the carrier gas valve allow sufficient gas through to allow for adequate flushing? • Is the carrier gas valve sealed? • Carry out a pump adjustment for pump P2. • Is the gas circuit leak-tight? Carry out a leakage test. Input error C1>C2 Input value for C1 is greater than for C2 • Enter the correct concentrations. Calibration marked with an asterisk IR signal is less than 75 % of the value for C2 from the last adjustment • Replace the standard solution for C2. Repeat the calibration. Internal comfault 1 I/O not responding during INIT process • Switch off the main switch and, after a short period of time, switch it back on again. If the error persists, contact E+H Service. Internal comfault 2 I/O not responding during NOINIT process • Switch off the main switch and, after a short period of time, switch it back on again. If the error persists, contact E+H Service. Internal comfault 10 KEYBOARD not responding • Switch off the main switch and, after a short period of time, switch it back on again. If the error persists, contact E+H Service. Internal comfault 20 CRC error between I/ O – CPU or between KEYBOARD – CPU • Switch off the main switch and, after a short period of time, switch it back on again. If the error persists, contact E+H Service. line 64 Endress+Hauser TOCII CA72TOC Maintenance 8 Maintenance To ensure efficient operation of the analyzer, maintenance must be carried out at regular intervals. Before attempting to service the device, you must be completely familiar with the maintenance processes and have perfectly understood the tasks involved. All the maintenance tasks described in this chapter should only be carried out by suitably trained specialists. Mistakes made during maintenance can result in inaccurate operation and pose a safety hazard. Interval Maintenance task At least once per week • Visual inspection • Check sample conditioning (see corresponding Operating Instructions) At least once per month • Check feed rate of pump P1/P4 and P2 • Replace standard Every 3 months at the latest • • • • • If salt quantity > 1 g/l, then perform the following every 3 months at the latest: • Replacing the acid filter • Replace catalyst • Clean combustion pipe 1 x per year • Replace filter pads in ventilators (do not clean) • Replace membrane filter (gas filter) Clean strip and separation chamber Replace glass bead Adjust pH sensor Replace pump hoses Check the filter pads in the ventilators and replace if necessary. The maintenance intervals depend greatly on your application. For this reason, adapt the maintenance intervals to your specific requirements but make sure to perform these maintenance tasks regularly! Endress+Hauser 65 Maintenance TOCII CA72TOC Flow chart Use this chart as reference if you have to replace or reconnect pipes or tubes. a0012369-en Fig. 25: 66 Flow chart Endress+Hauser TOCII CA72TOC Maintenance Interior views a0011861 Fig. 26: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ! Display and operating elements Main switch Display and operating elements USB connection Pump P2 sample analysis Junction box Compressor switch Ventilator Separation chamber Dosing valve Ventilator Injection unit Acid filter Tube furnace with catalyst Air outlet (filter pad) Combined filter (water trap) 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Heated salt trap (optional) Circuit gas flowmeter Dilution water pump P5 (optional) Acid hose connector MV4 calibration standard changeover C1/C2 MV1 wastewater/calibration standard changeover Valve for online sample/manual sample Pump P3, acid dosing Pump P4, sample - dilution (optional) Mixing chamber (optional) Pump P1, sample - strip chamber/condensate extraction Condensate hose connector Strip chamber with pH electrode Sample conditioning WARNING The device is energized. Touching current-carrying components may result in injury or death. ‣ First switch off the main switch. Then open the rear of the device with the special key provided. Endress+Hauser 67 Maintenance TOCII CA72TOC a0012022 Fig. 27: 1 2 3 4 5 6 7 8 9 10 11 12 13 68 Rear of device Peltier cooler Peltier cooler - glass insert Motor controller P1 to P6 Peltier cooler - control unit Membrane compressor Motor P2 sample - analysis Computer unit Power distribution Magnetic stirrer control pH - amplifier MV7 carrier gas flushing MV3 stripping gas supply Gas connection block 14 15 16 17 18 19 20 21 22 23 24 Restrictor stripping gas Restrictor carrier gas Motor P1, sample - strip chamber / condensate drainage Check valve Motor P4, sample - dilution (optional) Motor P3 acid dosing MV5 bypass flushing Water connection manifold IR detector Leak detector contacts Motor P5, dilution water pump (optional) Endress+Hauser TOCII CA72TOC Maintenance 8.1 Cleaning the housing Clean the analyzer housing as follows: • Use a fluoride-free and solvent-free cleaning agent and a lint-free cloth. 8.2 ! Visual inspection WARNING There is a risk of infection when working with wastewater! ‣ For this reason, wear protective goggles, protective gloves and protective clothing. ! CAUTION There is a risk of injury due to hot components! ‣ Wear heat-resistant gloves when in contact with hot components in the vicinity of the combustion furnace.. Carry out the visual inspection at least once a week: • Check whether the measurement is operating in the standard range. • Is the sample supply OK? To check, hold a collecting vessel under the valve and set the valve briefly to "Manual sample". Does the sample flow out of the bypass? • Is sample being dosed into the furnace? • Are hoses P1 to P3 (optionally P4) leak-tight? • Is sufficient C1 and C2 standard still available? • Is sufficient stripping acid still available? • If the condensate is being collected in a container, check if the container if full. • Check the gas supply. Pressure regulator at 2 bar (29 psi)? Circuit gas (right flowmeter) at 0.7 to 1.2 l/min (0.18 to 0.32 gal/min)? • Is the water supply pressure between 3 ±0.2 bar (43 ±3 psi)? • Is the acid filter free of condensate and not severely discolored? • Check stripping gas bubbling. • Does the rotating slit filter rotate uniformly? • Is a slit visible between the rotating body and the base of the chamber? a0012724 Fig. 28: Endress+Hauser Rotating slit filter a0012723 Fig. 29: Rotating slit filter, detailed view 69 Maintenance TOCII CA72TOC 8.3 ! Topping up reagents CAUTION There is a risk of injury when working with reagents. ‣ Observe the warnings on the safety data sheets. ‣ Wear acid-resistant protective gloves, protective goggles and a protective laboratory coat! ‣ In addition, adhere to the regulations applicable in your country and to your line of work governing the handling of caustic chemicals. Rinse off splashes immediately with plenty of water and 1 % sodium hydrocarbonate solution. Consult a physician and show him/ her the information on the canister. Only use original canisters for measurement. No liability is accepted for damage resulting from the use of other chemicals. The stripping reagent and standards C1 and C2 must be topped up or replaced. To prepare the reagents, see the "Preparing the chemicals" section. Parent solution • 5 000 mg/l TOC; for preparing standard solutions 1 and 2 Order number: 1000 ml (33.8 fl.oz.): CAY451-V10C01AAE • 100 000 mg/l TOC; for preparing standard solutions 1 and 2 Order number: 1000 ml (33.8 fl.oz.): CAY451-V10C10AAE Stripping reagent • Stripping reagent for CA72TOC Order number: 1000 ml (33.8 fl.oz.): CAY450-V10AAE 70 Endress+Hauser TOCII CA72TOC Maintenance 8.4 Replacing the standard This section describes how the standard solutions are replaced. Step Display 1 2 Description BYPASS SCREEN stops the measuring operation. BYPASS-SCREEN Change the standard solution as follows: 1. Remove the canister for the standard solution. MAINTENANCE COMPLETED ? 2. Dispose of any remaining standard solution. 3. Rinse the canister with deionized water. 4. Fill up the canister with new standard solution. [E] TO CONFIRM 5. Position the canister at the designated place. 6. Press the [E] key. Operation starts. If you have changed the concentration of the standard solution, enter the new concentration in the "Measuring range data" menu item and then trigger an adjustment. Endress+Hauser 71 Maintenance TOCII CA72TOC 8.5 Entering the concentration of the standard solution This section describes how the concentration of the standard solution is entered. Select the programming mode for this purpose: Step Display Description 1 2 72 • Enter the values for STANDARD C1 and STANDARD C2. Endress+Hauser TOCII CA72TOC Maintenance 8.6 Service menu The maintenance tasks are supported by the service software. This menu software is split into four sections: Endress+Hauser Pumps Replace hose P1/P4 Replace hose P2 Replace hose P3 Adjust P2 Calibration Analyzer adjustment Analyzer calibration Empty volume dosing Adjustment pH sensor Cleaning Screen flush Power flush Bypass screen Strip and separation chamber Opening the circuit Combustion pipe Leakage test Filter Replacing the acid filter Replacing the gas filter Replacing the O2 filter Replacing the heated filter 73 Maintenance TOCII CA72TOC 8.7 Pumps 8.7.1 Replacing the hoses on pumps P1 and P4 This section describes how the hoses of pumps P1 and P4 are replaced and the delivery rate is determined. ! CAUTION Danger of crushing! ‣ Never reach into the pump head while the pump is in operation! P1 P4 a0012483 Fig. 30: Position of pumps P1 and P4 You require the following parts: • 10 ml graduated cylinder • 2.5 mm Allen key • Dosing nozzle (injector) • Paper to absorb liquids • Collecting vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid • Silicone grease 74 Endress+Hauser TOCII CA72TOC Maintenance 4 5 3 2 6 7 1 8 a0012364 Fig. 31: 1 2 3 4 Pump P1 Pump retainer Pump head Hose cassette (sample hose) Hose cassette (condensate hose) 5 6 7 8 Motor Condensate hose (BK-BK) 0.76 mm (0.03") ID Sample hose (VT-WH) 2.79 mm (0.11") ID Adjusting screw Pump P1: The sample hose to the strip chamber has an internal diameter of 2.79 mm (0.11") with violet-white (VT-WH) color coding and the condensate drain hose has an ID of 0.76 mm (0.03") with black-black (BK-BK) color coding. Pump P4 (only for "With predilution" version): sample hose to the static mixer 2.79 mm (0.11") with VT-WH color coding. Step Display Description 1 Endress+Hauser 75 Maintenance TOCII CA72TOC Step Display 2 Description ! WARNING There is a risk of infection when working with wastewater! Wear protective gloves, goggles and protective clothing. ‣ Press the [E] key. The strip and separation chambers are flushed with pressurized water. 3 REPLACE HOSE P1/4 SWITCH VALVE TO MANUAL SAMPLING, PUT COLLECTING VESSEL BELOW 1. Set the sample valve to manual sampling. 2. To empty the pump hose and the strip chamber, place a collecting vessel under the hose connection for manual sampling. 3. Press the [E] key. [E] TO CONFIRM 4 For versions "with predilution": 1. First open the hose cassettes for pump 1. 2. Now open the hose cassette for pump 4. 3. Drain the strip chamber. 4. Press the [E] key. 76 Endress+Hauser TOCII CA72TOC Maintenance Step Display Description For versions "without predilution": 1. Open the hose cassette for pump 1. 2. Drain the strip chamber. 3. Press the [E] key. 5 REPLACE HOSE P1/4 In areas with a low amount of dust: Grease the new hoses with a light coating of silicone grease. 1. Hold paper under the strip chamber and mixer hose connection. REPLACE PUMP HOSE 2. Release the pump hoses (items 6 + 7) from the connections. 3. Replace the hoses. 4. Press the [E] key. [E] TO CONFIRM 6 For versions "with predilution": REPLACE HOSE P1/4 CLOSE HOSE CASSETTE(S) P1 CLOSE HOSE CASSETTE P4 CONNECT LOWER HOSES FILL HOSE WITH SAMPLE [>] START/STOP PUMP 4 (100%) [E] TO CONFIRM Continue with Step 6 for versions "with predilution". Continue with Step 14 for versions "without predilution". 1. Lock the hose cassettes in place in the retainer. 2. Make sure the hose cassette is seated correctly in the retainer. 3. Connect the P1 and P4 suction sides. 4. Press the [>] key to fill the hose with sample. 5. Check the drip pattern (even feed rate). You can now check the contact pressure of the hose cassette: 1. Release the adjusting screw (item 8) until no more medium is conveyed. 2. Now tighten the adjusting screw until the unit starts to pump medium again. Even medium delivery should be visible across all pump heads. 3. Tighten the adjusting screw one revolution. Endress+Hauser 77 Maintenance TOCII CA72TOC Step 7 Display REPLACE HOSE P1/4 Description If required, you can measure the capacity of pump hose P4. 1. Secure or hold the 10 ml graduated cylinder close to pump P4. IF REQUIRED, MEASURE CAPACITY OF HOSE P4 PREVIOUS VOLUME DELIVERED x.x ml 2. Guide hose P4 into the graduated cylinder. 3. Press the [>] key so pump P4 is operating at 100% capacity for 60 s. [>] START/STOP PUMP 4 (60sec) [E] TO CONFIRM You can enter the new value after 60 seconds. The value typically lies between 5.5 and 7 ml (0.18 and 0.24 fl.oz). REPLACE HOSE P1/4 The amount entered is displayed so you can check it is correct. Press the [E] key. NEW VOLUME DELIVERED x.x ml [>] START/STOP PUMP 4 (60sec) [E] TO CONFIRM 8 REPLACE HOSE P1/4 SHUT STRIP CHAMBER INLET WITH SEPARATE PLUG 1. Seal the strip chamber inlet with a separate plug (e.g. plug for leak test). 2. Connect hose P4 at the pressure side. 3. Press the [E] key. CONNECT HOSE P4 [E] TO CONFIRM 78 Endress+Hauser TOCII CA72TOC Maintenance Step 9 Display Description 1. Use the dosing nozzle of the injector to expand the hose end of the condensate hose. 2. Connect the suction side of the condensate hose and place the pressure side of the condensate hose into a glass containing water. 3. Press the [>] key to fill the sample hose with sample. 4. Check the drip pattern of the sample hose and check the air bubbles in the glass of water (even feed rate). You can now check the contact pressure of the hose cassette: 1. Release the adjusting screw (item 8) until no more medium is conveyed (air bubbles). 2. Now tighten the adjusting screw until the unit starts to pump medium again. Even medium delivery should be visible across all pump heads. 3. Tighten the adjusting screw one revolution. 4. Reconnect the pressure side of the condensate hose. 10 If required, you can measure the capacity of pump hose P1. 1. Secure or hold the 10 ml graduated cylinder close to pump P1. 2. Guide hose P1 into the graduated cylinder. 3. Press the [>] key so pump P1 is operating at 100% capacity for 60 s. You can enter the new value after 60 seconds. The value typically lies between 5.5 and 7 ml (0.18 and 0.24 fl.oz). Endress+Hauser 79 Maintenance TOCII CA72TOC Step Display Description Press the [E] key. 11 1. Connect hose P1 at the pressure side. 2. Press the [E] key. 12 1. Set the manual valve on the bypass to sampling. REPLACE HOSE P1/4 SWITCH VALVE TO BYPASS 2. Pump the sample out of the bypass with pump P4 until dilution. 3. Press the [E] key. FILL HOSE WITH SAMPLE [>] START/STOP PUMP 4 (100%) [E] TO CONFIRM 13 Stabilize dilution REPLACE HOSE P1/4 Continue with Step 18. XXX STABILIZE DILUTION 80 Endress+Hauser TOCII CA72TOC Maintenance Step 14 Display Description For versions "without predilution": 1. Lock the hose cassettes in place in the retainer. 2. Make sure the hose cassette is seated correctly in the retainer. 3. Use the dosing nozzle of the injector to expand the hose end of the condensate hose. 4. Connect the P1 suction side. 5. Set the sample tap to bypass. 6. Place the pump side of the condensate hose into a glass of water. 7. Press the [>] key to fill the hose with sample. 8. Check the drip pattern of the sample hose and check the air bubbles in the glass of water (even feed rate). You can now check the contact pressure of the hose cassette: 1. Release the adjusting screw (item 8) until no more medium is conveyed (air bubbles). 2. Now tighten the adjusting screw until the unit starts to pump medium again. Even medium delivery should be visible across all pump heads. 3. Tighten the adjusting screw one revolution. 4. Reconnect the pressure side of the condensate hose. 15 If required, you can measure the capacity of pump hose P1. 1. Secure or hold the 10 ml graduated cylinder close to pump P1. 2. Guide hose P1 into the graduated cylinder. 3. Press the [>] key so pump P1 is operating at 100% capacity for 60 s. You can enter the new value after 60 seconds. The value typically lies between 5.5 and 7 ml (0.18 and 0.24 fl.oz). Endress+Hauser 81 Maintenance TOCII CA72TOC Step Display Description Enter the new feed rate. Press the [E] key. 16 1. Connect hose P1 at the pressure side. 2. Press the [E] key. 17 1. Set the manual valve to bypass. 2. Using pump P1, pump the sample as far as the strip chamber. 3. Press the [E] key. 18 82 Automatic filling of the strip chamber, conditioning of the strip chamber with active acid dosing Endress+Hauser TOCII CA72TOC Maintenance 8.7.2 Replacing the hose on pump P2 This section describes how the hose of pump P2 is replaced. The following service menus are automatically started when this service menu finishes: 1. Adjusting pump P2 2. Empty volume dosing ! CAUTION Danger of crushing! ‣ Never reach into the pump head while the pump is in operation! a0012484 Fig. 32: Position of pump P2 You require the following parts: • 10 ml graduated cylinder • 2.5 mm Allen key • Dosing nozzle (injector) • Paper to absorb liquids • Collecting vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid • Silicone grease Endress+Hauser 83 Maintenance TOCII CA72TOC 6 5 4 2 1 3 a0014230 1 2 3 Pump retainer Pump head Sample hose (BK-BK) 0.76 mm (0.03") ID 4 5 6 Adjusting screw Hose cassette Motor Pump P2: Pumps sample from the separation chamber into the furnace. Hose: (BK-BK) 0.76 mm (0.03") Step Display Description 1 2 ! WARNING When working with wastewater, there is a risk of infection! Wear protective gloves, goggles and protective clothing. ‣ Press the [E] key. 84 Endress+Hauser TOCII CA72TOC Maintenance Step 3 Display Description The hose is drained automatically. REPLACE HOSE P2 XX PLEASE WAIT PUMP CONVEYS BACKWARDS [E] TO CONFIRM 4 REPLACE HOSE P2 1. Open the cover of the separation chamber. 2. Empty the separation chamber with the syringe (part of the scope of supply). EMPTY SEPARATION CHAMBER USING NOZZLE! 3. Press the [E] key. [E] TO CONFIRM 5 REPLACE HOSE P2 REPLACE PUMP HOSE In areas with a low amount of dust: Grease the new hoses with a light coating of silicone grease. 1. Release the hose at the injection unit and at the separation chamber. 2. Disengage the hose cassette. 3. Change the hose. 4. Use the dosing nozzle of the injector to expand the hose end. 5. Engage the hose cassette. [E] TO CONFIRM 6 6. Press the [E] key. 1. Seal the separation chamber. 2. Connect the hose at the suction side. 3. Start the service menu "Adjust pump P2" or press the [E] key to quit the service menu. Endress+Hauser 85 Maintenance TOCII CA72TOC Step 7 Display REPLACE HOSE P2 Description 1. Press the [>] key to fill the hose with sample. 2. Check the drip pattern (even feed rate). FILL HOSE WITH SAMPLE If a steady flow of medium does not occur, check the contact pressure of the hose cassette: 1. Release the adjusting screw (item 4) until no more medium is conveyed. [>] START/STOP PUMP 2 (100%) [E] TO CONFIRM 2. Now tighten the adjusting screw until the unit starts to pump medium again. Even medium delivery should be visible across all pump heads. 3. Tighten the adjusting screw one revolution. Press the [E] key. 8 1. Connect the hose P2 to the injection unit 2. Press the [E] key. Measuring operation is started automatically. The accuracy of the feed rate of pump P2 affects the measurement result. For this reason, start the following service menus in the order indicated once the pump hose has been replaced: 1."Adjust pump 2" 2."Empty volume dosing" Please also note that the hoses are subject to deterioration in the first hours of operation. For this reason, repeat these maintenance tasks after 24 hours. 86 Endress+Hauser TOCII CA72TOC Maintenance 8.7.3 Replacing the hose on pump P3 This section describes how the hose of pump P3 is replaced. ! CAUTION Danger of crushing! ‣ Never reach into the pump head while the pump is in operation! ! CAUTION Risk of injury due to acid ‣ Wear acid-resistant protective gloves, protective goggles and protective clothing! NOTICE Failure to comply may result in incorrect measurements ‣ No medium containing TOC should enter the acid feeder! a0012485 Fig. 33: Position of pump P3 You require the following parts: • Acid-resistant protective gloves, protective goggles and protective clothing • 10 ml graduated cylinder • 2.5 mm Allen key • Dosing nozzle (injector) • Paper to absorb liquids • Collecting vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid • Silicone grease Endress+Hauser 87 Maintenance TOCII CA72TOC 3 4 2 5 1 6 a0012368 Fig. 34: 1 2 3 Pump P3 Pump retainer Pump head Hose cassette 4 5 6 Motor Acid hose (BK-BK) 0.76 mm (0.03") ID Adjusting screw Pump P3: Pumps acid from the feeder tank into the strip chamber. Hose: (BK-BK) 0.76 mm (0.03") Step Display Description 1 2 ! CAUTION Risk of injury due to acid! Wear acid-resistant protective gloves, protective goggles and protective clothing. Rinse areas splashed with acid immediately with plenty of water and 1 % sodium hydrocarbonate solution. Consult a physician and show him/her the information on the canister. ‣ Press the [E] key. The strip and separation chambers are flushed with pressurized water. 88 Endress+Hauser TOCII CA72TOC Maintenance Step 3 Display REPLACE HOSE P3 EMPTY STRIP CHAMBER BY DISCONNECTING HOSE CONNECTION OF SAMPLE PUMP P1 AT THE STRIP CHAMBER PLACE VESSEL BELOW TO COLLECT CONTENT OF STRIP CHAMBER Description 1. Release the hose connection from pump P1 to the strip chamber. 2. Have a vessel at the ready to collect the liquid. 3. Drain the strip chamber. 4. Press the [E] key. [E] TO CONFIRM 4 REPLACE HOSE P3 DANGER! ACID REMOVE ACID SUCTION HOSE FROM ACID FEEDER AND PLACE VESSEL BELOW TO COLLECT ACID RELEASE HOSE CASSETTE P3 AND EMPTY ACID LINE Caution! Acid! 1. Remove the acid suction hose from the acid cistern and place the end in a collecting vessel. 2. Release the hose cassette. 3. Make sure that the acid runs back into the collecting vessel. NOTICE Failure to comply may result in incorrect measurements. No medium containing TOC should enter the acid feeder! ‣ [E] TO CONFIRM 5 4. Press the [E] key. In areas with a low amount of dust: Grease the new hoses with a light coating of silicone grease. 1. Release the pump hose from the connections. 2. Change the hose. 3. Press the [E] key. 6 REPLACE HOSE P3 1. Connect the hose of pump P1 to the strip chamber. 2. Press the [E] key. CONNECT SAMPLE HOSE PUMP P1 TO STRIP CHAMBER [E] TO CONFIRM Endress+Hauser 89 Maintenance TOCII CA72TOC Step Display Description 7 1. Rinse the suction hose of the acid pump. 2. Guide the suction tube into the acid feeder tank. 3. Insert the hose cassette into P3 and connect the hose to the hose connector. 4. Use the dosing nozzle of the injector to expand the hose end. 5. Press the [>] key until acid enters the strip chamber. 6. Make sure medium is being conveyed evenly in the suction hose. You can now check the contact pressure of the hose cassette: 1. Release the adjusting screw (item 6) until no more medium is conveyed. 2. Now tighten the adjusting screw until the unit starts to pump medium again. Even medium delivery should be visible across all pump heads. 3. Tighten the adjusting screw one revolution. Continue with Step 8 for versions "with predilution". Continue with Step 10 for versions "without predilution". 8 Dilution stabilizes for 120 s. REPLACE HOSE P3 XXX STABILIZE DILUTION 9 REPLACE HOSE P3 XX FILL HOSE WITH SAMPLE 90 Endress+Hauser TOCII CA72TOC Maintenance Step 10 Display Description Automatic filling of the strip chamber, conditioning of the strip chamber with active acid dosing REPLACE HOSE P3 XX Measuring operation is started automatically. FILL STRIP AND SEPARATION CHAMBERS Endress+Hauser 91 Maintenance TOCII CA72TOC 8.7.4 Adjusting pump P2 This section describes how the feed rate of pump P2 is determined. The "Empty volume dosing" service menu is started automatically when this service menu finishes: ! CAUTION Danger of crushing! ‣ Never reach into the pump head while the pump is in operation! a0012484 Fig. 35: Position of pump P2 You require the following parts: • 10 ml graduated cylinder • 2.5 mm Allen key • Dosing nozzle (injector) • Paper to absorb liquids • Collecting vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid 92 Endress+Hauser TOCII CA72TOC Maintenance 6 5 4 2 1 3 a0014230 Fig. 36: 1 2 3 Pump P2 Pump retainer Pump head Sample hose (BK-BK) 0.76 mm (0.03") ID Step Display 4 5 6 Adjusting screw Hose cassette Motor Description 1 2 ! CAUTION There is a risk of infection when working with wastewater! For this reason, wear protective goggles, protective gloves and protective clothing. ‣ Press the [E] key. Endress+Hauser 93 Maintenance TOCII CA72TOC Step 3 Display Description 1. Release hose P2 at the dosing needle. 2. Hold a collecting vessel under the hose. 3. Start pump P2 with the [>] key. 4. Fill the hose until an even amount of sample exits the hose. No air bubbles should be conveyed. Make sure that even dosage takes place over all the rollers of the pump head. 5. Stop the pump as soon as a steady flow of medium is pumped. If a steady flow of medium does not occur, you can check the contact pressure of the hose cassette: 1. Release the adjusting screw (item 4) until no more medium is conveyed. 2. Now tighten the adjusting screw until the unit starts to pump medium again. Even medium delivery should be visible across all pump heads. 3. Tighten the adjusting screw one revolution. 4 1. Place a graduated beaker underneath the end of the dosing tube. 2. Press the [E] key to start timecontrolled dosage. 5 94 Pump P2 pumps at 100 % for 10 minutes. Endress+Hauser TOCII CA72TOC Maintenance Step 6 Display Description ADJUSTMENT PUMP 2 ENTER ml ? Enter the delivery volume determined. The value typically lies between 8.5 and 9.5 ml (0.29 and 0.32 fl.oz). [E] TO CONFIRM 7 Press the [E] key. 8 1. Connect hose P2. 2. Press the [E] key (the "Empty volume dosing" service menu is started). The accuracy of the feed rate of pump P2 affects the measurement result25 For this reason, the "Empty volume dosing" service menu is started once pump P2 has been adjusted. Endress+Hauser 95 Maintenance TOCII CA72TOC 8.7.5 Cleaning dilution water pump P5 If you use deionized water as the dilution medium, pump P5 only has to be cleaned as part of the annual maintenance work performed by Endress+Hauser Service. If you are using drinking water as the dilution medium, the maintenance intervals may be reduced depending on the water hardness level. In this case, contact Endress+Hauser Service a0014102 Fig. 37: 96 Position of pump P5 Endress+Hauser TOCII CA72TOC Maintenance 8.8 Adjusting 8.8.1 Adjusting the analyzer This section describes how the analyzer is adjusted. The analyzer is adjusted using two-point adjustment. Two different standard solutions are measured for this purpose. These standard solutions are connected in the analyzer. Adjustment procedure: 1. The basic line is measured. 2. The analyzer measures the concentration of standard C1. 3. The basic line is measured. 4. The analyzer measures the concentration of standard C2. 5. The offset X0 and the slope Kp are calculated from these values. Measuring signal = CO2(C) = CO2(dose) - CO2(base line) a0012547-en Fig. 38: Calculation of the measuring signal X0 = CO2(C1) - C1 CO2(C2) - CO2(C1) (C2 - C1) a0012549 Calculation of the offset X0 Kp = C2 CO2(C2) - X0 actual dosing volume 0.3125 a0012548-en Fig. 39: Calculation of the standardized slope Kp Measured signal Kp X0 C1 C2 Concentration a0012550-en Fig. 40: Adjustment curve CO2(C1) = CO2 concentration of the measurement of standard C1. CO2(C2) = CO2 concentration of the measurement of standard C2. The offset and the reciprocal standardized slope of the adjustment curve (measuring signal per concentration) are saved in the maintenance record log under ADJUSTMENT CONSTANTS. Analyzer adjustment can be started in three ways: • Activated manually • Activated remotely • Activated automatically Endress+Hauser 97 Maintenance TOCII CA72TOC Manually activated adjustment Step Display Description 1 Remotely activated adjustment Adjustment can be triggered by a floating contact. Use input 2 of the "binary in" terminal strip for this purpose. I 1 1 II 2 1 2 0/4-20 mA + 0/4-20 mA + binary in 2 III 1 IV binary out 2 40 - 41 - 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND RS 232 a0011911 Fig. 41: 1 2 3 4 98 Signal connection Calibration, external activation Adjustment, external activation Screen flush, external activation Power flush, external activation 5 6 7 8 Not assigned Not assigned Standby, external activation Channel switchover, external activation (optional) Endress+Hauser TOCII CA72TOC Maintenance Automatically activated adjustment The analyzer can be adjusted automatically. Select the programming mode for this purpose: Step Display Description 1 2 Endress+Hauser • For CAL./ADJUST. n DAYS, specify the number of days after which an adjustment is to be performed. It is generally not necessary to select more than one adjustment every three days. • Enter the value 2 for CAL./ ADJUSTM. Value 1 = Calibration Value 2 = Adjustment 99 Maintenance TOCII CA72TOC 8.8.2 Calibrating the analyzer This section describes how the analyzer is calibrated. The analyzer checks the current recovery by measuring the standard solution C2. In contrast to adjustment, the adjustment constants are not changed. The standard solution C2 is connected to the analyzer. Analyzer calibration can be started in three ways: • Activated manually • Activated remotely • Activated automatically Manually activated calibration Step Display Description 1 Remotely activated calibration Calibration can be triggered by a floating contact. Use input 1 of the "binary in" terminal strip for this purpose. I 1 1 II 2 1 2 0/4-20 mA + 0/4-20 mA + binary in 2 III 1 IV binary out 2 40 - 41 - 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND RS 232 a0011911 Fig. 42: 1 2 3 4 100 Signal connection Calibration, external activation Adjustment, external activation Screen flush, external activation Power flush, external activation 5 6 7 8 Not assigned Not assigned Standby, external activation Channel switchover, external activation (optional) Endress+Hauser TOCII CA72TOC Maintenance Automatically activated calibration The analyzer can be calibrated automatically. Select the programming mode for this purpose: Step Display Description 1 2 • For CAL./ADJUST. n DAYS, specify the number of days after which a calibration is to be performed. It is generally not necessary to select more than one calibration every three days. • Enter the value 1 for CAL./ ADJUSTM. Value 1 = Calibration Value 2 = Adjustment Analog value output during calibration During calibration, the last TOC value is transmitted to the analog output and held until the calibration value has been determined. The calibration value is then transmitted to the analog output (or to analog output channel 1 in the two-channel version) until a new measured value is determined for the current sample. During calibration, relay IV (OPERATION CHECK) is opened until a new measured value is available in measuring mode. If the analog output is used for control purposes, this OPERATION CHECK signal can be used to declare the analog output as invalid. Endress+Hauser 101 Maintenance TOCII CA72TOC 8.8.3 Empty volume dosing Use this service menu to determine the dead volume of pump P2 from the separation chamber to the end of the capillary. a0012487 Fig. 43: Step Position Display Description 1 2 The hose of pump P2 is drained. 3 The pump pumps automatically in the direction of the capillary. Pumping stops if: a) A drop is detected or b) The system times out after 180 s. In the event of a), continue with Step 4. In the event of b), continue with Step 6. 102 Endress+Hauser TOCII CA72TOC Maintenance Step 4 5 6 Display Description The new volume value determined appears on the display. The value, including the volume and time, is entered in the EMPTY VOLUME DOSING log. The value determined is saved in the EMPTY VOLUME P2 [μl] parameter. Measuring operation is started once you confirm with the [E] key. "Empty volume dosing" ends. The system has timed out. Determine the empty volume manually. The service is restarted and the automatic determination function is disabled. Empty volume dosing can now be carried out manually. Endress+Hauser 7 The pump is drained. 8 Start the pump with the [E] key. 103 Maintenance TOCII CA72TOC Step Description 9 Stop the pump with the [E] key when the first drop falls. 10 The new volume value determined appears on the display. The value, including the volume and time, is entered in the EMPTY VOLUME DOSING log. The value determined is saved in the EMPTY VOLUME P2 [μl] parameter. 11 104 Display Measuring operation is started once you confirm with the [E] key. "Empty volume dosing" ends. Endress+Hauser TOCII CA72TOC Maintenance 8.8.4 Adjustment pH sensor This section describes how to remove and install the pH sensor, and how to perform twopoint adjustment on the pH sensor. a0012478 Fig. 44: Position of the sensor To adjust the pH sensor, you require: • Deionized water • Buffer solution pH = 4.00 • Buffer solution pH = 7.00 • Paper towels to absorb liquid • Vessel to collect liquids 1 2 3 4 a0012176 Fig. 45: 1 2 3 4 Endress+Hauser Strip chamber and separation chamber pH sensor Cover Thread adapter nut Strip chamber 105 Maintenance TOCII CA72TOC Step Display Description 1 2 1. Release the thread adapter nut (3) on the strip chamber (4). ADJUSTMENT pH SENSOR 2. Remove the cover (2) with the pH sensor (1) from the strip chamber. RELEASE COVER OF STRIP CHAMBER 3. Press the [E] key. CAREFULLY REMOVE SENSOR [E] TO CONFIRM 3 1. Rinse the sensor with deionized water. 2. Hold the sensor in the buffer solution pH = 4.00. 3. Press the [E] key. 4 1. Wait until the measured value stabilizes (a bar appears to the right of the measured value). ADJUSTMENT pH SENSOR 2. Press the [E] key. MEASURED VALUE X.XX [E] TO CONFIRM 106 Endress+Hauser TOCII CA72TOC Maintenance Step Display Description 5 1. Rinse the sensor with deionized water. 2. Hold the sensor in the buffer solution pH = 7.00. 3. Press the [E] key. 6 1. Wait until the measured value stabilizes (a bar appears to the right of the measured value). ADJUSTMENT pH SENSOR 2. Press the [E] key. Calculation of the calibration values. Typical slope value: between 55 mV/ decade and 58 mV/decade MEASURED VALUE X.XX [E] TO CONFIRM 7 ADJUSTMENT pH SENSOR 1. Put the pH sensor into the strip chamber. 2. Screw the cover of the strip chamber closed hand-tight. 3. Press the [E] key. RE-INSERT pH-SENSOR Operation starts. [E] TO CONFIRM The following appears on the display if the adjustment failed: Endress+Hauser 107 Maintenance TOCII CA72TOC Step Display Description The adjustment constants are not accepted. • Check the buffer solutions. • Check the sensor or • Replace the sensor. Repeat the adjustment. 108 Endress+Hauser TOCII CA72TOC Maintenance 8.9 Cleaning 8.9.1 Screen flush In the version with the pipe back flushing option, water is supplied via the solenoid valve MV1. This means that, in addition to the sample conditioning system, the pipe is backflushed all the way to the bypass screen. a0012726 Fig. 46: Position of the screen Screen flushing runs automatically after startup, and can be started in three ways: • Activated manually • Activated remotely • Activated automatically Manual activation of screen flush Step Display Description 1 Endress+Hauser 109 Maintenance TOCII CA72TOC Remote activation of screen flush The screen flush can be triggered using a potential-free contact. Use input 3 of the "binary in" terminal strip for this purpose. I 1 1 II 2 1 2 0/4-20 mA + 0/4-20 mA + binary in 2 III 1 IV binary out 2 40 - 41 - 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND RS 232 a0011911 Fig. 47: 1 2 3 4 Signal connection Calibration, external activation Adjustment, external activation Screen flush, external activation Power flush, external activation 5 6 7 8 Not assigned Not assigned Standby, external activation Channel switchover, external activation (optional) Automatic activation of screen flush The screen flush can be triggered automatically. Select the programming mode for this purpose: Step Display Description 1 2 • For SCREEN FLUSH n/Day, enter the number of flushes per day. The factory setting is two screen flushes per day. Operation starts automatically on completion of the screen flush process. 110 Endress+Hauser TOCII CA72TOC Maintenance 8.9.2 Power flush During a power flush, the strip chamber and separation chamber are flushed with the connected pressurized water via solenoid valve MV2. a0012478 Fig. 48: Position of the strip and separation chamber Power flushing runs automatically after startup, and can be started in three ways: • Activated manually • Activated remotely • Activated automatically Manual activation of power flush Step Display Description 1 Endress+Hauser 111 Maintenance TOCII CA72TOC Remote activation of power flush The power flush can be triggered with a potential-free contact. Use input 4 of the "binary in" terminal strip for this purpose. I 1 1 II 2 1 2 0/4-20 mA + 0/4-20 mA + binary in 2 III 1 IV binary out 2 40 - 41 - 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND +24VDC GND RS 232 a0011911 Fig. 49: 1 2 3 4 Signal connection Calibration, external activation Adjustment, external activation Screen flush, external activation Power flush, external activation 5 6 7 8 Not assigned Not assigned Standby, external activation Channel switchover, external activation (optional) Automatic activation of power flush The power flush can be triggered automatically. Select the programming mode for this purpose: Step Display Description 1 2 • For POWER FLUSH n/Day, enter the number of flushes per day. The factory setting is two power flushes per day. Operation starts automatically on completion of the power flush process. 112 Endress+Hauser TOCII CA72TOC Maintenance 8.9.3 Bypass screen This section describes how the bypass screen is cleaned manually. a0012489 Fig. 50: 1 2 3 4 Sample conditioning Upper thread adapter nut Bypass elbow Lower thread adapter nut Bypass screen housing 5 6 7 8 Vent Bypass screen O-ring O-ring You require the following parts: • Bottle brush • Paper towels Step Display Description 1 Endress+Hauser 113 Maintenance TOCII CA72TOC Step 2 Display BYPASS-SCREEN Description ! WARNING There is a risk of infection when working with wastewater! Wear protective gloves, goggles and protective clothing. ‣ MAINTENANCE COMPLETED ? Clean the bypass screen as follows: 1. Shut off the supply of wastewater (external sample supply). [E] TO CONFIRM 2. Set the "Online sample/manual sample" valve to "Manual sample". Drain the bypass line. Set the valve back to the previous position. 3. Release the lower and upper thread adapter nut (items 1 +3). 4. Remove the bypass elbow (item 2). 5. Remove the bypass screen. 6. Clean the bypass screen and the housing with a brush. 7. Unscreen the vent and open it. Clean the vent and make sure the bead is able to move freely. 8. Insert the parts again in the reverse order. Make sure that the O-rings (items 7 and 8) are undamaged and are correctly positioned. 9. Switch the supply of wastewater back on. 10. Press the [E] key. Operation starts. 114 Endress+Hauser TOCII CA72TOC Maintenance 8.9.4 Strip and separation chamber This section describes how to manually clean the strip and separation chamber and replace the glass bead. a0012478 Fig. 51: Position of the strip and separation chamber You require the following parts: • 4 mm Allen key • Injector (part of the scope of supply) • Glass bead • Soft brush • Paper towels to absorb liquid • Vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid • Needle-nosed pliers Endress+Hauser 115 Maintenance TOCII CA72TOC a0012343 Fig. 52: 1 2 3 4 5 6 7 8 Strip and separation chamber pH sensor Strip chamber cover Strip chamber thread adapter nut Coupling Strip chamber Coupling (drain) Separation chamber thread adapter nut Separation chamber Step Display 9 10 11 12 13 14 15 16 17 Separation chamber cover Magnetic stir bar Glass bead Glass frit O-ring Coupling (stripping gas connection) Capillary Knurled head screw Seal Description 1 116 Endress+Hauser TOCII CA72TOC Maintenance Step 2 Display Description ! WARNING There is a risk of infection when working with wastewater! Wear protective gloves, goggles and protective clothing. ‣ Press the [E] key. 3 The strip and separation chamber are automatically flushed with pressurized water for 10 s. 4 1. Have a vessel at the ready to collect the liquid. 2. Release the hose connection of pump P1 at the strip chamber. 3. Hold the vessel in place and drain the strip chamber. 4. Absorb any drops of water with paper towels. 5. Press the [E] key. 5 1. Release the thread adapter nut (item 3) on the strip chamber. 2. Release the cable of the pH sensor. 3. Remove the cover (item 2) with the pH sensor (item 1) from the strip chamber (item 5). 4. Release the coupling (item 14) and remove the coupling and the glass frit (item 12). 5. Release the coupling (item 6) and take off the hose coupling. 6. Release the thread adapter nut (item 7) and remove the cover (item 9). Endress+Hauser 117 Maintenance TOCII CA72TOC Step Display Description 7. Use the pliers to remove the magnetic stir bar (item 10) from the separation chamber (item 8). 8. Empty the separation chamber (item 8) with the injector (withdrawn by suction). 9. Connect the empty injector to the suction needle for the sample (connection P2). 10. Using the injector, inject air quickly and force the glass bead out of the bore hole. To make it easier to remove the glass bead, you can release the coupling (item 4) and release the separation chamber from the strip chamber. 11. Clean the chambers with a soft brush. In the event of severe fouling, you can separate the strip chamber and separation chamber from one another by releasing the securing screw. For complete removal, you must disconnect the connector of the magnetic stirrer controller. 12. Clean the pH sensor (see the Brief Operating Instructions of the pH sensor). 13. Insert a new glass ball. 14. Insert the magnetic stir bar. The thin shaft points upwards. 15. Release the knurled head screw (item 16) and remove the capillary (item 15). 16. Insert a new capillary. Slide in the capillary as far as it will go. Ensure that the seal (item 17) is seated correctly in the knurled head screw Tighten the knurled head screw. 17. Fit the hose (P2) onto the capillary. 18. Put the cover on the separation chamber and tighten the thread adapter nut hand-tight. 19. Put the drain pipe onto the coupling and screw the coupling (item 6) closed. 20. Insert the pH sensor and connect the cable. 21. Screw the thread adapter nut hand-tight. 22. Clean the glass frit or replace it. Reinstall the glass frit, the O-ring (item 13) and the coupling. 23. Press the [E] key. 6 1. Connect the hose of pump P1 to the strip chamber. 2. Press the [E] key. 7 POWER FLUSH XX The strip and separation chamber are automatically flushed with pressurized water for 180 s. Measuring operation then starts automatically. FILL STRIP AND SEPARATION CHAMBERS Adjust the pH sensor after cleaning the strip and separation chamber (see the "Adjusting the pH sensor" section). 118 Endress+Hauser TOCII CA72TOC Maintenance 8.9.5 Opening the circuit This section describes how the dosing head (capillary) is cleaned or replaced. The furnace temperature is not reduced. The system continues to perform sample conditioning (stripping). a0012498 Fig. 53: Position of the dosing unit You require the following parts: • Damp cloth 3 5 4 1 2 a0012492 Fig. 54: 1 2 3 4 5 Endress+Hauser Dosing Red screw plug Capillary O-ring O-ring Dosing head 119 Maintenance TOCII CA72TOC Step Display Description 1 2 OPENING THE GAS CIRCUIT Clean the needle as follows: 1. Remove the hose P2 from the capillary of the dosing head. MAINTENANCE COMPLETED ? [E] TO CONFIRM 2. Release the red screw plug (item 1). 3. Remove the dosing head (item 5). 4. Using a damp cloth, remove the salt residue on the capillary or replace the capillary. When installing the capillary (item 2), ensure that the capillary is protruding from the bottom of the dosing head by approx. 10 mm (0.4 "). 5. Check the O-ring (item 4), and also check the O-ring (item 3) if replacing the capillary. 6. Insert the dosing head and tighten the red screw plug. 7. Fit the hose P2 onto the capillary. 8. Press the [E] key. Operation starts. 120 Endress+Hauser TOCII CA72TOC Maintenance 8.9.6 Combustion pipe This section describes how the combustion pipe is cleaned and replaced, or how the entire furnace is replaced. The furnace heating system is switched off. a0012530 Fig. 55: Position of the furnace You require the following parts: • Auxiliary tool for the combustion pipe insert • Crucible tongs • Heat-resistant gloves • Dust mask FFP3 Endress+Hauser 121 Maintenance TOCII CA72TOC a0012387 Fig. 56: Furnace 1 Dosing head 6 2 3 4 5 Red screw plug with O-ring Furnace cover Thread adapter nut Furnace outlet with O-ring 7 8 9 10 Step 1 Display Knurled head screw with support and sealing ring Clamp screw Optional heated salt trap Safety guard Combustion pipe Description ! CAUTION Inhalation of catalyst dust poses a health hazard. Wear a breathing mask when replacing the catalyst. ‣ 122 Endress+Hauser TOCII CA72TOC Maintenance Step 2 Display Description ! COMBUSTION PIPE CAUTION Contact with hot parts of the combustion furnace may cause injury! Use heat-resistant gloves. ‣ REMOVE HOSE P2 FROM FURNACE The power supply for the combustion furnace is switched off. The furnace cools down. 1. Release the hose at the dosing head (item 1). 2. Press the [E] key. [E] TO CONFIRM 3 ! COMBUSTION PIPE TEMPERATURE OPEN FURNACE [E] TO CONFIRM = XXX CAUTION Contact with hot parts of the combustion furnace may cause injury! Use heat-resistant gloves. ‣ °C If the insert in the combustion pipe is removed when very hot (over 300 °C), cracks may form in the insert and the combustion pipe if they cool down too quickly. This results in a higher basic line and has a negative impact on the operation of the measuring device. 1. If a heated salt trap is installed, release the hose connection and the electrical collection at the heated salt trap. 2. Remove the safety guard. 3. Swivel the furnace outwards. 4. Pull the heated salt trap down from the furnace outlet by turning it gently back and forth. 5. Swivel the furnace back in and lock it. 6. When the temperature has dropped to approx. 300 °C, slacken the lower knurled head screw (item 6). 7. Allow the furnace to cool to below 50 °C (not necessary if replacing the furnace). 8. Press the [E] key. If you are replacing the entire furnace, proceed with Step 4a. If you are cleaning or replacing the combustion pipe, proceed with Step 4b. Endress+Hauser 123 Maintenance TOCII CA72TOC Step 4a Display Description Only if replacing the furnace: ! CAUTION Contact with hot parts of the combustion furnace may cause injury! Use heat-resistant gloves. COMBUSTION PIPE ‣ TEMPERATURE = XXX MAINTENANCE COMPLETED? [E] TO CONFIRM °C 1. Detach the outflow hose on the mounting plate or on the salt trap, if a heated salt trap (optional) is fitted. 2. Release the locking button on the furnace and swivel the furnace outwards. 3. Release the electrical plug-in connections between the analyzer and the furnace. 4. Remove the furnace. 5. Press the [E] key. Continue with Step 7. 124 Endress+Hauser TOCII CA72TOC Maintenance Step 4b Display Description Only if cleaning or replacing the combustion pipe: ! CAUTION Contact with hot parts of the combustion furnace may cause injury! Use heat-resistant gloves. COMBUSTION PIPE ‣ TEMPERATURE = XXX MAINTENANCE COMPLETED? [E] TO CONFIRM °C 1. If a heated salt trap is not fitted, release the hose connection between the furnace outlet (item 5) and the mounting plate. 2. Remove the knurled head screw (item 6). Remove the furnace outlet and the O-ring from the combustion pipe. 3. Release the red screw plug (item 2) and remove the dosing head (item 1). 4. Remove the safety guard. 5. Release the thread adapter nut on the furnace entry (item 4) and remove the furnace cover. 6. Remove the O-ring and support ring. 7. Unlock the furnace and pull it out. 8. Using the auxiliary tool, pull the combustion pipe insert approx. 10 mm (0.4") out of the combustion pipe. Then remove the combustion pipe insert using the crucible tongs, and take out the filling. Put the waste in a container for inorganic materials. Dispose of the used catalyst as hazardous waste in accordance with local laws and safety regulations. Do not pour it down the drain or into a garbage can! 9.Lift the combustion pipe under the furnace and using the crucible tongs remove it from the furnace from the top. 10. If necessary, clean the combustion pipe using a brush. Endress+Hauser 125 Maintenance TOCII CA72TOC Step 5 Display Description Reassembling the combustion unit 1. Insert the combustion pipe into the tube furnace. 2. Place the combustion pipe insert with filler (approx. 25 g high-temperature catalyst) into the combustion pipe. 3. Check and clean the support ring and sealing ring for the furnace cover and insert the sealing ring and the support ring. 4. Fit the cleaned furnace cover and the thread adapter nut on the furnace entry and tighten the thread adapter nut. 5. Mount the dosing head with the O-ring, and tighten the red screw plug. 6. If you are not using the optional heated salt trap, fit the furnace outlet with a glass fiber fabric as the salt trap. Roll two fabrics together loosely and put the fabrics loosely into the furnace outlet. Approx. 10 mm (0.4") must remain free at the top end to catch the salt. 7. If you are using the optional heated salt trap, leave the furnace outlet empty. 8. Insert the cleaned furnace outlet and a clean O-ring into the combustion pipe and tighten the knurled head screw hand-tight. 9. If you are not using the optional heated salt trap, connect the hose from the furnace outlet to the bulkhead gland on the mounting plate. 6 If you are using the optional heatable salt trap: 1. Turn the salt trap gently to push it onto the furnace outlet nozzle. 2. Make sure that the seal seals the glass nozzle with a slight suction effect. You can adjust the seal with the clamp screw. The seal should not be too tight however. 3. Push the salt trap under the furnace. 4. Fold down the retaining bar and rest the filter on the bar. 5. Plug in the electrical contact and lock it. 6. Fit the hose on the heatable salt trap and screw it down. Press the [E] key. 7 1. Once you have replaced the entire furnace, connect the hose to the mounting plate or to the heated salt trap (optional). Connect the electrical plug-in connections between the furnace and the analyzer. 2. Move the furnace into position and secure it. 3. Press the [E] key. 126 Endress+Hauser TOCII CA72TOC Maintenance Step 8 Display Description 1. Install the hose at the injection unit. 2. Check that the hose is correctly inserted in the magnetic valve 8. 3. Press the [E] key. 9 The carrier gas valve MV7 (relay #7) is opened as soon as 85% of the set temperature is reached. The system flushes permanently with carrier gas. Sample conditioning takes place (strip chamber) after the furnace is being heated. Operation starts automatically. Now carry out a leakage test (see "Leakage test" section). Endress+Hauser 127 Maintenance TOCII CA72TOC 8.9.7 Leakage test This section describes how the gas circuit is checked for leaks. Check the leak-tightness of the gas circuit after each modification to the furnace. You require the following parts: • Drain plug from the accessories supplied 1 2 a0012531 Fig. 57: 1 2 Left-hand side of the housing Gas outlet Switch for membrane compressor Step 1 Display Description S E R V I C E PUMPS CALIBRATION CLEANING FILTERS 2 SCREEN FLUSH POWER-FLUSH BYPASS-SCREEN STRIPPER+SEPARATION OPEN GAS CICUIT COMBUSTION PIPE LEAKAGE TEST LEAKAGE TEST 1. Switch off the membrane compressor (item 2). 2. Seal the gas outlet with a plug (left-hand side panel, item.1). SWITCH MEMBRANE COMPRESSOR OFF 3. Press the [E] key. SHUT GAS OUTLET [E] TO CONFIRM 128 Endress+Hauser TOCII CA72TOC Maintenance Step Display Description 3 Press the [->] key. The carrier gas valve is opened and pressure is applied to the gas circuit. The pressure is shown on the display. The carrier gas valve is closed automatically: • If the pressure has exceeded 100 mbar or • Once 7 seconds have elapsed. If the pressure does not reach 100 mbar, this indicates a sizable leak. 4 LEAKAGE TEST CARRIER VALVE SHUT x.xxx mbar/min XXX mbar XX [E] TO CONFIRM sec The pressure loss rate is displayed (mbar/min) after 30 s. The pressure loss must be < 3 mbar/ min. Values are typically between 0.5 and -2.0 mbar/min. If the loss in pressure is > 3 mbar/ min, divide the gas circuit into smaller sections. Bridge the individual components using a hose, and repeat the leakage test until you have found the leak. If there is no pressure loss in a bridged component e.g. a component of the furnace with the salt trap, the leak is in the bridged component. Press the [E] key. 5 LEAKAGE TEST 1. Remove the plug from the gas outlet (left-hand side panel). 2. Switch on the membrane compressor. OPEN GAS OUTLET SWITCH MEMBRANE COMPRESSOR ON 3. Press the [E] key. Operation starts. [E] TO CONFIRM Endress+Hauser 129 Maintenance TOCII CA72TOC Possible points where a leak might be present: • Furnace seals • Acid filter seal at the glass • Condensate drain • Water block filter To find the leak, the following tools in the "Maintenance tool kit" (see "Spare parts" section) are available for the purpose of bridging components: • Hose D 3/5 mm FPM • Hose connector 1/8 - 1/8 PP To seal the gas outlet at the furnace: • Protective cap • Reducing adapter 8/4 mm, straight To seal the gas outlet at the cabinet: • Locking cap M3 EPDM 130 Endress+Hauser TOCII CA72TOC Maintenance 8.10 Filter 8.10.1 Replacing the acid filter This section describes how the acid filter is replaced. Replace the acid filter: • If it is blocked or worn out. This is noticeable from the flow rate and pressure level of the gas circuit. • If zinc or copper become completely and obviously discolored. a0012500 Fig. 58: Position of the acid filter You require the following parts (part of the wear parts kit): • Glass fiber fabric • Zinc pellets • Copper powder 1 5 5 5 6 6 6 2 3 7 4 8 a0012316 Fig. 59: 1 2 3 4 Endress+Hauser Acid filter Coupling Retaining clip Filter glass body GL coupling 5 6 7 8 Glass fiber fabric Zinc Copper Glass fiber fabric 131 Maintenance TOCII CA72TOC Step Display Description 1 2 REPLACE ACID FILTER ! CAUTION Risk of injury due to aggressive materials. Wear protective gloves! ‣ MAINTENANCE COMPLETED ? 1. Release the couplings (items 1 and 4). 2. Remove the acid filter (item 3) from the retaining clips (item 2). 3. Remove the filling in the acid filter. 4. Clean the glass if necessary. [E] TO CONFIRM 5. Roll the fabric into a roll and push it into the filter glass (item 8). Do not press it in too hard. Shorten the fabric if necessary. 6. Fill the glass up to the halfway mark with copper and then with zinc (see order of items 6 and 7). Allow enough room for the second piece of fabric. 7. Roll the fabric into a roll and use it to close the filling in the acid filter (item 5). 8. Clean the O-rings and seal the acid filter. Make sure that the fabric does not extend as far as the plug to ensure the filter housing is sealed properly (see zoom detail of  å 59). 9. Fit the acid filter into the retaining clips and connect the filter. 10. Press the [E] key. Operation starts (initially without a measured value). 132 Endress+Hauser TOCII CA72TOC Maintenance 8.10.2 Replacing the gas filter This section describes how the gas filter is replaced. Replace the gas filter if it is blocked. a0012500 Fig. 60: Position of the gas filter 1 IN 2 3 OUT a0012307 Fig. 61: 1 2 3 Endress+Hauser Gas filter Coupling Gas filter Coupling 133 Maintenance TOCII CA72TOC Step Display Description 1 2 REPLACE GAS FILTERS 1. Release the couplings (items 1 and 3). 2. Replace the gas filter (item 2). Take the direction of flow into account. MAINTENANCE COMPLETED ? 3. First secure the filter in the coupling (item 3) and then connect the filter to the acid filter with the coupling (item 1). Make sure that the cone is properly positioned on the filter. [E] TO CONFIRM 4. Tighten the two couplings. Operation starts (initially without a measured value). 134 Endress+Hauser TOCII CA72TOC Maintenance 8.10.3 Replacing the O2 filter This section describes how the O2 filter is replaced. The gas connection block with the O2 filter is mounted on the rear of the analyzer. You require the following parts: • Open-ended wrench • Needle-nosed pliers 1 2 3 a0012321 Fig. 62: 1 2 3 Gas connection block with O2 filter Gas connection block O2 filter Coupling Step Display Description 1 2 ! CAUTION Risk of injury due to release of pressure Wear protective goggles! ‣ 1. Close the valve for the carrier gas supply. 2. Relieve the pressure on the pressure line before opening the hose connection to prevent injury from the uncontrolled release of pressure. 3. Press the [E] key. Endress+Hauser 135 Maintenance TOCII CA72TOC Step 3 Display Description 1. Release the coupling (item 3). REPLACE O2 FILTER 2. Check the O2 filter (item 2) for possible signs of wear. Replace the filter if necessary. 3. Screw the coupling into the gas connection block. MAINTENANCE COMPLETED ? 4. Press the [E] key. [E] TO CONFIRM 4 1. Reconnect the gas supply. 2. Open the gas supply valve. 3. Press the [E] key. 5 PLEASE WAIT 6 The analyzer display switches to step 6 after 10 seconds. REPLACE O2 FILTER XX The furnace heats up. Measuring operation starts automatically as soon as 90% of the set temperature is reached and the CO2 value has dropped below the threshold value. During this time, sample conditioning takes place (strip chamber) and pH regulation is activated Measuring operation commences if these two conditions are met. 136 Endress+Hauser TOCII CA72TOC Maintenance 8.10.4 Replacing the heated salt trap This section describes how to replace the heated salt trap (referred to as "heated filter" in the menu). a0012515 Fig. 63: Position of heated salt trap You require the following parts: • 4 mm Allen key • Deionized water • Heat-resistant gloves 3 3 4 5 6 a0012516 Fig. 64: 1 2 7 Endress+Hauser Heated salt trap when installed Retaining bracket Heated salt trap with insulation Clamp screw a0012517 Fig. 65: 3 4 5 6 Heated salt trap, open Allen screws Filter housing, top section Filter cartridge O-ring 137 Maintenance TOCII CA72TOC To ensure that the furnace does not cool down too much during the cleaning process, it is heated between the point the salt trap is removed and the salt trap is installed. Extended measuring device downtime results if the furnace cools down too much, and should therefore be avoided. Step Display Description 1 2 ! CAUTION Contact with hot parts of the combustion furnace may cause injury! Use heat-resistant gloves. ‣ Carry out the following tasks quickly to ensure the furnace does not cool down too much: 1. Release the hose connections on the dosing head. 2. Unlock the furnace and swivel it outwards. 3. Release the electrical connection to the salt trap. 4. Press the [E] key. 3 Confirm that you disconnected the electrical connection to the salt trap. The furnace is reheated and the temperature displayed. 138 Endress+Hauser TOCII CA72TOC Maintenance Step 4 Display Description 1. Release the hose at the outlet of the heated salt trap. 2. Raise the salt trap (item 2) slightly. 3. Fold back the retaining bracket (item 1). 4. Remove the salt trap (item 2) from below. 5. Remove the insulation. 6. Release the two screws (item 3) and remove the top part of the filter housing (item 4). 7. Clean the inside of filter cartridge (item 5) and the filter housing with deionized water. 8. Clean the O-ring (item 6) and fit it back into the groove. 9. Screw the filter housing together and insert it into the insulation. 10. Press the [E] key. 5 Carry out the following tasks quickly to ensure the furnace does not cool down too much: 1. Fit the salt trap on the glass nozzle of the furnace. 2. Make sure that the seal seals the glass nozzle with a slight suction effect. You can adjust the seal with the clamp screw (item 7). The seal should not be too tight however. 3. Push the salt trap under the furnace. 4. Fold down the retaining bar and rest the salt trap on the bar. 5. Reestablish the electrical connection. 6. Press the [E] key. 6 The furnace is reheated and the temperature displayed. 1. Connect the hose to the outlet of the salt trap. 2. Swivel the furnace back and ensure that the hose passes comfortably through the rear panel and is not buckled. 3. Lock the furnace. 4. Reestablish the hose connection at the dosing head. 5. Press the [E] key. Endress+Hauser 139 Maintenance TOCII CA72TOC Step 140 Display Description 7 The analyzer waits until the temperature is 30 ° below the set temperature. 8 Press the [E] key to start measuring operation. Endress+Hauser TOCII CA72TOC Maintenance 8.10.5 Replacing the filter pads in the ventilators This section describes how the filter pads in the ventilators are checked and replaced. a0021275 Fig. 66: Position of filter pads To replace the filter pads, you will require the following parts: • Replacement filter pad AM 115P (2x) • Replacement filter pad AM 335P (1x) Proceed as follows: Endress+Hauser 1. Remove the safety guard (no tool necessary). 2. Check if the filter pads are soiled. 3. Replace the soiled filter pads. 4. Put the safety guard back in. Ensure that the ventilation slits on the safety guard are pointing down. 141 Repair TOCII CA72TOC 9 Repair 9.1 Spare parts pH electrode for strip chamber Order No.: CPS71-1TB2GSA Wear parts kit for one year Order No: 71095156 for versions with standard furnaces 142 Name Quantity Flange seal D 53.9 x 63 x 3.1 mm 1 O-ring D 36.09 x 3.53 mm FKM 1 O-ring D 1.5 x 1.5 mm FPM 2 O-ring D 8 x 2 mm FPM 1 Capillary 1.6 x 0.8 x 71 mm AL23 1 Catalyst 800 - 900 °C 75 g pack 1 Cone for coupling 1/8" 28 UNF ETFE 2 Coupling with nozzle 1/4"-28 D1.55 ETFE 4 Coupling with nozzle 1/4"-28 D3.20 ETFE 2 Fiberglass precut part, acid filter 24 x 230 mm 8 Copper, powder 50g pack 2 Zinc, granules, 60g pack 2 O-ring D 33 x 3 mm EPDM 1 O-ring D 12 x 1.5 mm EPDM 1 Filter cartridge 12 x 1 mm frit, porosity 4 1 O-ring D 35 x 3 mm EPDM 1 Capillary 1.6 x 0.8 x 45 mm AL23 1 Membrane for solenoid valve 330 A EPDM 2 Hose cassette, Ismatec CA71 2 Hose 2.79 / 4.59 PharMed violet/white 4 Hose 0.76 / 2.36 PharMed black/black 12 Glass balls D 2 mm 10-piece pack 1 Replacement filter pad AM 115P, air outlet 2 Replacement filter pad AM 335P, air outlet 1 Replacement membrane filter (gas filter) 1 Dust mask FFP3 3 Endress+Hauser TOCII CA72TOC Repair Name Quantity Locking cap M3 EPDM 1 Protective cap 1 Order no.: 71095149 for versions with heated salt trap Contains all the parts of 71095156 and also: Name Quantity O-ring D 64 x 2.5 mm FPM 1 Seal, glass tube heating filter 1 Filter sleeve, 25 x 64 20μ PTFE 2 Coupling D 4/6 G1/8 PP 1 Maintenance tool kit Order No.: 71102317 Endress+Hauser Name Quantity Locking cap M3 EPDM 1 Hose D 3/5 mm FPM 0.6 Protective cap 1 Hose connector 1/8 - 1/8 PP 2 Dosing needle D 0.84 mm, green 1 Injector 20 ml 1 Hose iD 1/2 mm Tygon 400 mm 1 Auxiliary tool for the salt trap 1 Crucible tongs 200 mm in length 1 Heat-resistant gloves (1 pair) 1 Gloves, resistant to acids and bases, large (1 pair) 1 Installation tool for seal set 1 Reducing adapter 8/4 mm, straight 1 143 Repair TOCII CA72TOC Wear parts kit for strip and separation chamber Order No.: 71101606 Name Quantity O-ring D 1.5 x 1.5 mm FPM 1 O-ring D 8 x 2.5 mm FPM 1 O-ring D 33 x 3 mm EPDM 1 O-ring D 12 x 1.5 mm EPDM 1 Filter cartridge 12 x 1 mm frit, porosity 4 1 O-ring D 35 x 3 mm EPDM 1 Capillary 1.6 x 0.8 x 45 mm AL23 2 Glass balls D 2 mm 10-piece pack 1 Stirrer support, complete, for 100 μ particles 1 Wear parts kit for acid filter Order No.: 71101607 Name Quantity Zinc, granules, 60g pack 3 Copper, powder 50g pack 3 Fiberglass precut part, acid filter 24 x 230 mm 2 Wear parts kit for predilution pump Order No.: 71101608 144 Name Quantity Coupling, short thread 1/8" - 28 UNF ETFE 1 Cone for coupling 1/8" - 28 UNF ETFE 1 Seal set D10 1 Endress+Hauser TOCII CA72TOC Repair 9.2 ! Decommissioning CAUTION There is a risk of infection if you come into contact with wastewater. ‣ Wear protective gloves, protective goggles and a protective laboratory coat! Proceed as follows to take the analyzer out of service: 1. Switch off the wastewater pump. 2. If sample preparation is present: Trigger a screen flush (CLEANING - SCREEN FLUSH). Allow the bypass to drain. 3. Optional dilution water pump P5: Flush the pump with 5 % acid followed by DI water. Use the TEST menu to control pump P5. You can pump the acid and the DI water directly out of the feeder tank. 4. Flush the hoses. Set valve 1 to Manual sample and place a container with deionized water under the valve. TEST - TEST OF OUTPUTS - PUMPS Enter 400% for pump P1 and pump P4 (optional) and let the pumps pump for some time. Remove the acid hose of pump P3 from the acid canister and insert it into a container with deionized water. Also let this pump run at 400 % for some time. 5. Clean the vessels Trigger an automatic flush of the strip chamber (CLEANING - POWER FLUSH). Afterwards, perform manual cleaning of the strip and separation chamber (CLEANING - STRIPPER & SEPARATION). The pH sensor must be stored wet. Fill the protection cap with 3-mole KCl solution and fit the protection cap onto the sensor. 6. Empty the hoses Open the hose cassettes of pumps P1, P2, P3 and (if optional dilution takes place) P4. Let the rinse water run out of the hoses. Remove the canister with the standard. TEST - TEST OF OUTPUTS - SWITCH OUTPUTS Switch the switch outputs SA1 and SA4 to "ON". Wait until the pipes for standard 1 and 2 are empty. Switch the switch outputs "OFF" again. Remove the feeder tank. 7. Switch off the main switch on the analyzer. 8. Empty the combustion pipe insert Empty the combustion pipe insert (see "Maintenance - Combustion pipe" section). Do not dispatch the analyzer with the combustion pipe insert still inserted (risk of breakage). Empty the glass insert. Assemble the combustion unit. 9. Remove the exhaust (if present). 10. Close off the carrier gas supply. Relieve the pressure on the pressure line before opening the hose connection to prevent injury from the uncontrolled release of pressure. Unscrew the hose for the carrier gas supply on the left side panel. Detach the hose on the pressure-reducing valve of the carrier gas cylinder or gas preparation system. Endress+Hauser 145 Repair TOCII CA72TOC 9.3 Return The product must be returned if repairs or a factory calibration are required, or if the wrong product was ordered or delivered. Due to legal specifications and as an ISO-certified company, Endress+Hauser is required to follow certain procedures when handling all returned products that have been in contact with medium. To ensure that your device is returned swiftly, safely and in an appropriate manner, please read the procedures and conditions on the Endress+Hauser website at www.services.endress.com/return-material 9.4 Disposal The device contains electronic components and must therefore be disposed of in accordance with regulations on the disposal of electronic waste. Please observe local regulations. 146 Endress+Hauser TOCII CA72TOC Accessories 10 Accessories Reagents ‣ CAY450-V10AAE, 1000 ml stripper reagent für CA72TOC ‣ CAY451-V10C01AAH, 1000 ml parent solution 5,000 mg/l TOC ‣ CAY451-V10C10AAH, 1000 ml parent solution 100,000 mg/l TOC Technical buffer solutions, accuracy 0.02 pH, according to NIST/DIN ‣ ph 4.00; 20 x 18 ml (0.68 fl. oz); order no. CPY20-C01A1 ‣ ph 7.00; 20 x 18 ml (0.68 fl. oz); order no. CPY20-E01A1 Furnace conditioning station 230 V AC 50/60 Hz order number: 71103492 115 V AC 50/60 Hz order number: 71103493 ‣ ‣ Standard furnace To be used as a second furnace or as a substitute Cannot be used with heated salt trap Order number: 71091188 ‣ ‣ ‣ Furnace for heated salt trap To be used as a second furnace or as a substitute Order number: 71103888 ‣ ‣ Kit CA72TOC heated salt trap As replacement for maintenance (decreases the maintenance time) or as replacement Order number: 71101532 ‣ ‣ Endress+Hauser 147 Technical Data TOCII CA72TOC 11 Technical Data 11.1 Input Measured variable TOC (TC possible without stripping unit) Measuring range Version Measuring range A 0.25 to 600 mg TOC/l B 1 to 2400 mg TOC/l C 2.5 to 6000 mg TOC/l D 5 to 12000 mg TOC/l With optional predilution, the measuring range can be expanded by a factor of 20. Signal inputs 8 signal inputs 24 V DC, active, load max. 500  Input #1 Service, trigger calibration Input #2 Service, trigger adjustment Input #3 Service, trigger screen flush Input #4 Service, trigger power flush Input #5 Input #6 11.2 Input #7 Trigger standby Input #8 Trigger channel switchover (optional) Output Output signal Measuring channel 1: 0/4 to 20 mA, galvanically isolated Measuring channel 2 (for two-channel version): 0/4 to 20 mA, galvanically isolated Load: max. 500  Data interface RS 232 C, proprietary, for data output and remote operation (optional) Alarms 4 outputs: Limit value alarm, fault message, standby message and operating check, potential-free, normally closed (max. 0.25 A / 50 V) 11.3 Power supply Supply voltage 115/230 V AC, 50/60 Hz, 800 VA Fuses Assembly Fuses Power distribution 2.5 A, slow-blow, design: fine-wire fuse 6.3 x 32 Relay 4 A per relay, slow-blow, design: TR5 Power unit 2 A, slow-blow, design: fine-wire fuse 5 x 20 TOCII CA72TOC is suitable for connection to industrial power supply systems in accordance with EN 61326-1, Class A. 148 Endress+Hauser TOCII CA72TOC Technical Data 11.4 Performance characteristics In accordance with ISO 15839 The performance characteristics have been determined in accordance with ISO 15839, Annex B. 300 μl sample were metered into the TOCII (CA72TOC-B1A0B1) per measurement. This resulted in a measuring range from 4 to 800 mg/l. The following data refer to this device. Slight deviations should be factored in if applying the performance characteristics to other measuring ranges. LOD (limit of detection) 0.75 % of end of measuring range LOQ (limit of quantitation) 2.5 % of end of measuring range Short-term drift 0.5 %/day Repeatability precision at 20 % of the measuring range 0.4 % Resolution limit at 20 % of the measuring range (LDC) 1.1 % Systematic measured value deviation at 20 % of the measuring range (BIAS) 0.4 % Repeatability precision at 80 % of the measuring range 1.6 % Resolution limit at 80 % of the measuring range (LDC) 4.6 % Systematic measured value deviation at 80 % of the measuring range (BIAS) 2.4 % 11.5 Ambient temperature range 5 to 35 °C (41 to 95 °F) Humidity 20 to 80 %, non-condensing Degree of protection IP 54 11.6 Process Sample temperature 4 to 40 °C (39 to 104 °F) Sample flow rate 20 ml/min (0.32 US gal/hr) Sample feeder volume 90 ml (3 fl.oz) PA-2, PA-3 and PA-9 are available for selection as sample preparations. Sample consistency Aqueous Flammable substances should not occur in combustible concentrations - sample dilution is then necessary. Sample supply Non-pressurized infeed to the analyzer from sample preparation. 11.7 Endress+Hauser Environment Mechanical construction Weight Approx. 75 kg (165 lbs) Material Housing Aluminum, powder-coated (RAL7035) Window Glass, conductive coating Valve seals EPDM, FPM, FFKM Pump hoses Ismapren Pumps and pump seals PTFE, FFKM Reagent and sample hoses PTFE, PE Exhaust gas and ventilation hoses PTFE, PE Outflow hoses PTFE 149 TOCII CA72TOC Index A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Adjusting pump P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Adjusting the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Adjusting the pH sensor . . . . . . . . . . . . . . . . . . . . . . . . . 105 ALARM LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ALARM RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 B BASIC DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Bypass screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 C Calibrating the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 100 Check Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation and function. . . . . . . . . . . . . . . . . . . . . . . 34 Citric acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 109 Combustion pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 COMPLETE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Compressed air and water supply . . . . . . . . . . . . . . . . . . 10 Connection Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 H Hose replacement P1 and P4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 I Incoming acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 19 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 K Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 L Leakage test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 LISTS ALARM RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 COMPLETE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . 42 MAINTENANCE RECORD. . . . . . . . . . . . . . . . . . . . . . . 45 MIN MAX AVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 47 RECORD ALL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 M Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Filter pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Adjusting the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 97 Adjusting the pH sensor . . . . . . . . . . . . . . . . . . . . . . 105 Bypass screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Calibrating the analyzer . . . . . . . . . . . . . . . . . . . . . . 100 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Combustion pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Empty volume dosing . . . . . . . . . . . . . . . . . . . . . . . . 102 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Opening the circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Power flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Replacing the acid filter . . . . . . . . . . . . . . . . . . . . . . 131 Replacing the filter pads. . . . . . . . . . . . . . . . . . . . . . 141 Replacing the gas filter . . . . . . . . . . . . . . . . . . . . . . . 133 Replacing the heated filter . . . . . . . . . . . . . . . . . . . . 137 Replacing the O2 filter . . . . . . . . . . . . . . . . . . . . . . . 135 Screen flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Service software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Strip and separation chamber . . . . . . . . . . . . . . . . . 115 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 MAINTENANCE RECORD. . . . . . . . . . . . . . . . . . . . . . . . . . 45 Measuring range adjustment . . . . . . . . . . . . . . . . . . . . . . 55 MEASURING SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Methods of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MIN MAX AVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 G N D Declaration of conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Designated use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Device designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . 60 Dilution water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Dosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 E Electrical technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Empty volume dosing . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Error messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 F Gas flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 150 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Endress+Hauser TOCII CA72TOC O Opening the circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 P Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pivoting frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Post-connection check . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Potassium hydrogen phthalate . . . . . . . . . . . . . . . . . . . . 16 Power flush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Preparing chemicals Chemicals preparation . . . . . . . . . . . . . . . . . . . . . . . . 15 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Programming mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 T Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 TEST INPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Two-channel External changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Time-controlled changeover . . . . . . . . . . . . . . . . . . . . 53 U Updating the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 W Wall mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Workplace safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 R RANGE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Reagent quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Recording mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Replacing the acid filter . . . . . . . . . . . . . . . . . . . . . . . . . 131 Replacing the gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Replacing the heated filter . . . . . . . . . . . . . . . . . . . . . . . 137 Replacing the O2 filter . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 S Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Salt load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Screen flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Set brightness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SET CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Set contrast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SETTING ALARM LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 BASIC DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 MEASURING SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 RANGE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 SET BRIGHTN./CONTR.. . . . . . . . . . . . . . . . . . . . . . . . 41 SET CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Signal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Spot view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Standard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Standard concentrations. . . . . . . . . . . . . . . . . . . . . . . . . . 15 Standby mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Strip and separation chamber . . . . . . . . . . . . . . . . . . . . 115 Stripping reagent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Endress+Hauser 151 www.addresses.endress.com