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DOC026.53.80273
astroTOC UV/Turbo Analyzer
03/2012, Edition 1
User Manual
Table of Contents
Specifications
General information
..................................................................................................6
Installation
Electrostatic discharge (ESD) considerations ....................................................14
Connect the optional communications network card ..........................................19
Plumb the sample line and sample bypass ........................................................21
User interface and navigation
............................................................................23
Startup
1
Table of Contents
Operation
Schedule validations, calibrations and cleaning .................................................33
Select validation, calibration and cleaning options .............................................34
Select the amount of time for analyzer phases ..................................................35
Select the level criteria for alarms and analog output ranges ............................. 36
Set a condition to each relay and analog output ................................................37
Set a condition to each the analog output ...................................................37
Set a condition to each analog output for the EPA ...................................... 39
Set a condition to each output relay ............................................................39
Set a condition to each output relay for the EPA ......................................... 40
Change the tolerance settings (not recommended) ...........................................42
Primary and Manual calibration ...................................................................44
Active versus primary calibration % (Prim v cal) .........................................45
Maintenance
2
Table of Contents
Troubleshooting
Replacement parts and accessories
...............................................................71
Replacement pump kits
......................................................................................... 80
Pump kit 200117, 200118, 200120 and 5787000 ......................................................80
Pump kits 200119, 200138, 200140, 200142 and 5414700 ......................................82
Appendix
3
Table of Contents
4
Specifications
Specifications are subject to change without notice.
Specification
Dimensions (W x D x H)
Enclosure
Weight
Power requirements
Power cable
Maximum power consumption
Fuses
Pollution degree/overvoltage category
Operating temperature
Operating altitude
Storage temperature
Maximum relative humidity
Relays
Analog outputs
Analysis method
Measurement range (each model has a specific range)
Response time
Accuracy/Repeatability/Linearity
Method detection limit
Signal drift (60 days)
Sample pressure
Flow rate
Sample temperature
Carrier gas
Details
60 x 21 x 98.1 cm (26.6 x 8.3 x 38.6 in.)
Rating: NEMA 4X/IP66
Material: Cold-rolled epoxy powder-coated steel, optional stainless steel (304)
54 kg (120 lb)
Single phase, 115 or 230 VAC ±10%, 50/60 Hz (not rated for
BI or multi phase)
18–12 AWG
300 W
IEC127 Sheet III Type 2: 1 A anti-surge, 250 V; 2 A antisurge, 250 V; 4 A anti-surge, 250 V; 4 A quick blow, 250 V
2/II
5 to 40 °C (41 to 104 °F)
2000 m (6570 ft) maximum
5 to 40 °C (41 to 104 °F)
80% to 31 °C decreasing linearly to 50% at 40 °C
5 output relays and 1 input relay, 3 A at 250 VAC; 0.5 A at
30 VDC
Two analog outputs, user configurable, optically isolated, self powered. Maximum resistive load 600 Ω.
UV persulfate oxidation with acid sparging for TIC removal followed by CO
2
NDIR detector measurement
Standard: 0–5 to 0–20,000 mg/L TOC
Turbo: 0–50,000 µg/L (0-50 mg/L) TOC
Standard: T90 ≤ 8 minutes; T20 ≤ 3 minutes (rangedependent)
Turbo: T90 ≤ 5 minutes (0–5 mg/L); T20 ≤ 3 minutes
Standard: ±2%, full-scale undiluted; ±4%, full-scale diluted
Turbo: ≤ 4% or 8 µg/L (whichever is greater)
Standard: ≤ 0.015 mg/L at 0–5 mg/L 25 °C (77 °F)
Turbo: ≤ 5 μg/L at 0–5000 μg/L
< 2% with auto clean and auto calibration
At atmospheric pressure
25–200 mL/minute
25–60 mL/minute with an external cooler
2 to 70 °C (36 to 158 °F)
Clean, CO
2
-free air at 2.8 bar (40 psi) minimum to 3.8 bar
(55 psi) maximum. Recommended 3.1 bar (45 psi).
English 5
Specification
Carrier gas usage
Certifications
Warranty
Details
Standard: 450 mL/min in TOC mode; 250 mL/minute in TC mode
Turbo: approximately 380 mL/minute at atmospheric pressure
CE certified, Listed to UL and CSA safety standards by ETL
US: 1 year; EU 2 years
General information
In no event will the manufacturer be liable for direct, indirect, special, incidental or consequential damages resulting from any defect or omission in this manual. The manufacturer reserves the right to make changes in this manual and the products it describes at any time, without notice or obligation.
Revised editions are found on the manufacturer’s website.
Safety information
N O T I C E
The manufacturer is not responsible for any damages due to misapplication or misuse of this product including, without limitation, direct, incidental and consequential damages, and disclaims such damages to the full extent permitted under applicable law. The user is solely responsible to identify critical application risks and install appropriate mechanisms to protect processes during a possible equipment malfunction.
Please read this entire manual before unpacking, setting up or operating this equipment. Pay attention to all danger and caution statements. Failure to do so could result in serious injury to the operator or damage to the equipment.
Make sure that the protection provided by this equipment is not impaired. Do not use or install this equipment in any manner other than that specified in this manual.
Use of hazard information
D A N G E R
Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or serious injury.
W A R N I N G
Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious injury.
C A U T I O N
Indicates a potentially hazardous situation that may result in minor or moderate injury.
N O T I C E
Indicates a situation which, if not avoided, may cause damage to the instrument. Information that requires special emphasis.
6 English
Precautionary labels
Read all labels and tags attached to the instrument. Personal injury or damage to the instrument could occur if not observed. A symbol, if noted on the instrument, will be included with a danger or caution statement in the manual.
Electrical equipment marked with this symbol may not be disposed of in European public disposal systems after 12 August of 2005. In conformity with European local and national regulations (EU
Directive 2002/98/EC), European electrical equipment users must now return old or end-of-life equipment to the Producer for disposal at no charge to the user.
Note: For return for recycling, please contact the equipment producer or supplier for instructions on how to return endof-life equipment, producer-supplied electrical accessories, and all auxillary items for proper disposal.
This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential injury. If on the instrument, refer to the instruction manual for operation or safety information.
This symbol indicates the need for protective eye wear.
This symbol indicates that a risk of electrical shock and/or electrocution exists.
This symbol indicates the presence of devices sensitive to Electro-static Discharge (ESD) and indicated that care must be taken to prevent damage with the equipment.
This symbol, when noted on the product, identifies the location of a fuse or current limiting device.
This symbol indicates that the marked item requires a protective earth connection. If not provided with a plug on a cord, connect positive earth to this terminal (U.S. cord set provides ground).
Product overview
D A N G E R
Chemical or biological hazards. If this instrument is used to monitor a treatment process and/or chemical feed system for which there are regulatory limits and monitoring requirements related to public health, public safety, food or beverage manufacture or processing, it is the responsibility of the user of this instrument to know and abide by any applicable regulation and to have sufficient and appropriate mechanisms in place for compliance with applicable regulations in the event of malfunction of the instrument.
D A N G E R
Chemical hazard. Do not use the analyzer to measure samples that contain chlorine compounds as chlorine compounds react with UV light and produce harmful gases.
C A U T I O N
Chemical exposure hazard. The UV lamps in this instrument contain mercury. Dispose of chemical wastes in accordance with applicable local, regional and national regulations.
This instrument uses the EPA-approved UV persulfate oxidation method to measure total organic carbon (TOC) or total carbon (TC) in:
English 7
Standard units
• Boiler feed water
• Pharmaceutical process water
• Condensate and cooling water
• Bulk chemical
• Outfall units
• Industrial wastewater
• Industrial effluents
Turbo units
• Boiler feed water
• Pharmaceutical process water
• Condensate and cooling water
• Semiconductor reclaimed water
This instrument has an EPA mode to comply with the USEPA requirements for drinking water. The dual-stream inlet block must be used with the EPA mode. This instrument has two enclosures:
• Top enclosure for electronics (
• Bottom enclosure for liquids (
Figure 1 Top enclosure
1 8000 display/controller board
2 Infrared (IR) bench
3 8001 I/O board
4 Power supply
5 Surge suppressor
8 English
Figure 2 Side view and bottom enclosure
1 Single stream inlet block
2 Plumbing ports
3 Label for the plumbing ports
4 Condenser fan
5 Waste gas vent
6 Electrical access ports with plugs
7 Gas liquid separator (GLS)
8 Condenser
9 Pump module assembly and flow controller
10 UV lamp assembly
11 UV reactor manifold
12 Persulfate and resample pumps
13 Sparger manifold and pressure gauge
14 Acid and sample pumps
Product components
Make sure that all components have been received. Refer to Figure 3
. If any items are missing or damaged, contact the manufacturer or a sales representative immediately.
English 9
Figure 3 Instrument components
1 astroUV/Turbo analyzer
2 4-liter container (2x)
3 19-liter container (2x)
1
Put in the tool box.
The tool box contains:
• Quick reference card
• Cap and tubing assembly for 19-liter bottle (2x)
• Cap and tubing assembly for 4-liter bottle (2x)
• Modified cap for 4-liter bottle (2x)
• Drain pipe
• Cable strain relief fittings (2x)
• Fuse, 1 A
• Fuse, 4 A
• Hex ballend driver (4x)
• Nut driver
• Replacement tubing and fittings
• TC conversion parts
4 Tub
5 Tool box
6 Tubing loading key
1
Installation
D A N G E R
Multiple hazards. Only qualified personnel must conduct the tasks described in this section of the document.
Installation guidelines
Install the analyzer:
• In a dry, well ventilated, temperature controlled location
• As close to the sample source as possible to decrease analysis delay
• Near a drain and the carrier gas source
• Near a vent to outdoors to plumb the waste gas vent outdoors
• So that the power cable plug or power disconnect switch are visible and easily accessible
10 English
Mechanical installation
Lift the instrument
W A R N I N G
Personal injury hazard. Instruments or components are heavy. Use assistance to install or move.
Lift the instrument with a forklift. Put the blades of the forklift under the enclosure on each side of the drain. Make sure that the top of the enclosure does not tilt during travel.
Wall mounting
D A N G E R
Risk of injury or death. Make sure that the wall mounting is able to hold 4 times the weight of the equipment.
Mount the analyzer to a wall with the four mounting brackets on the analyzer.
Mount the analyzer so that the display is at or slightly above eye level.
Make sure that there is at least 400 mm (16 in.) of clearance on the sides and bottom, and 1000 mm
(40 in.) in the front of the analyzer. Refer to Figure 4
for dimensions.
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Figure 4 Analyzer dimensions
1 Single stream inlet block shown. 784.5 mm (30.9 in) with dual stream inlet block.
Optional rack mount
D A N G E R
Personal injury hazard. Make sure that the equipment is stable and use assistance to install and move.
Mount the analyzer to the rack with the four mounting brackets on the analyzer. Only use the rack
on page 79.
Make sure that there is at least 400 mm (16 in.) of clearance on the sides and bottom, and 1000 mm
(40 in.) in the front of the analyzer. Refer to
for dimensions.
12 English
Figure 5 Rack dimensions
Electrical installation
D A N G E R
Electrocution hazard. Always remove power to the instrument before making electrical connections.
D A N G E R
Electrocution hazard. If this equipment is used outdoors or in potentially wet locations, a Ground Fault
Circuit Interrupt (GFCI/GFI) device must be used for connecting the equipment to its main power source.
D A N G E R
Electrocution hazard. Protective Earth Ground (PE) connection is required.
Use shielded twisted-pair cable for all electrical connections except input power. Use of non-shielded cable may result in radio frequency emission or susceptibility levels higher than the allowed levels.
To prevent shock hazards from ground currents in inadequate ground systems, connect the shield at only the analyzer end. Do not connect the shield wire at both ends.
English 13
Electrostatic discharge (ESD) considerations
N O T I C E
Potential Instrument Damage. Delicate internal electronic components can be damaged by static electricity, resulting in degraded performance or eventual failure.
Refer to the steps in this procedure to prevent ESD damage to the instrument:
• Touch an earth-grounded metal surface such as the chassis of an instrument, a metal conduit or pipe to discharge static electricity from the body.
• Avoid excessive movement. Transport static-sensitive components in anti-static containers or packages.
• Wear a wrist strap connected by a wire to earth ground.
• Work in a static-safe area with anti-static floor pads and work bench pads.
Electrical access ports
Make electrical connections through the electrical access ports. Refer to Figure 2
on page 9.
Remove plugs as necessary.
To keep the environmental rating and for safety:
• Make sure that all electrical access ports that are not used have the supplied plugs installed.
• Use sealing-type PG11 fittings or equivalent for power cords, wiring and conduit. Refer to
on page 17.
Refer to
Specifications on page 5 for wire gauge requirements.
14 English
Wiring overview
Figure 6 8001 I/O board connections
1 Analog output connectors and links 4 Blowback valve connector
2 Location for optional communications card and JP1 5 Output relay connectors
3 Level detector connectors (REA1-REA3), level detector links (LK10-LK13) and input relay connector (SW1)
6 Communications card connectors
1
1
Use only when the optional communication card is installed.
Wiring for power
D A N G E R
Fire hazard. Install a 15 A circuit breaker in the power line. A circuit breaker can be the local power disconnect, if located in close proximity to the equipment.
English 15
W A R N I N G
Electrocution hazard. Only the hot (L) connection is fused. Connect only single phase power sources to equipment. Do not use bi-phase or poly-phase supply sources.
Connect power with conduit or a power cable. Refer to
For installation with conduit, install a power disconnect switch or circuit breaker near the analyzer and mark it as the disconnect device for main power to the analyzer.
For installation with a power cable, make sure that the power cable is:
• Less than 3 m (9 ft) in length
• Rated for at least 60 °C (140 °F) and applicable to the installation environment
• Not less than 18 AWG
• A power cable with a three-prong plug (with ground connection) that is applicable to the supply connection
• Connected through a cable gland (strain relief) that holds the power cable securely and seals the enclosure when tightened
• Does not have a locking type device so it can be used as the power disconnect device
16 English
Figure 7 Connect power
1 Cover screw (4x)
2 Surge suppressor cover
3 Power cable
4 Conduit fitting
5 Strain relief fitting for cables and wiring
6 Protective earth ground (G)
7 Neutral (N)
8 Hot (L)
9 Surge suppressor
Table 1 AC wiring information
Connection
Hot (L)
Neutral (N)
Protective earth ground (G)
Color—North America
Black
White
Green
Color—EU
Brown
Blue
Green with yellow stripe
Connect the relays (optional)
W A R N I N G
Potential Electrocution Hazard. Power and relay terminals are designed for only single wire termination.
Do not use more than one wire in each terminal.
English 17
C A U T I O N
Fire hazard. Relay loads must be resistive. Always limit current to the relays with an external fuse or breaker. Obey the relay ratings in the Specifications section.
C A U T I O N
Fire and electrical shock hazard. Obey relay load limitations of the external circuits specified in the
Specifications section. The circuit application will determine the wire gauge needed; however, wire gauge less than 18 AWG is not recommended.
The analyzer contains:
• Five output relays (S1–S5)—single-pole changeover relays with volt-free contacts
• One input relay (SW1)—normally open contact relay with volt-free contacts
Use the relays at either all high voltage (greater than 30 V-RMS and 42.2 V-PEAK or 60 VDC) or all low voltage (less than 30 V-RMS and 42.2 V-PEAK, or less than 60 VDC). Do not configure a combination of both high and low voltage.
Use the input relay to remotely control the analyzer (e.g., stop measurements or start an auto
calibration). Refer to Set a condition to the input relay on page 40.
Refer to
Table 2 to make relay connections.
Figure 8 Connect relays
1 Strain relief fitting for cables and wiring 2 Conduit fitting
18 English
NO
Normally open
Table 2 Output relay wiring
NC
Normally closed
COM (C)
Common
Connect the analog outputs (optional)
N O T I C E
Use double-insulated shielded cables to connect to external digital or analog circuits.
The analyzer contains two isolated analog outputs (CH1 and CH2). Use the analog outputs for analog signaling or to control external devices.
Assign the analog outputs to a measured parameter (i.e., pH, temperature, flow or calculated
values). Refer to Set a condition to each the analog output on page 37.
on page 15 to make analog output connections. Refer to
for wiring and load impedance specifications.
The default analog output is 4–20 mA (no jumpers). Install jumpers across the links as shown in
to change the analog outputs to 0–10 V or 4–20 mA with I– terminals connected to ground
(PE) as necessary.
If the configuration of the analog output jumpers is changed, it may be necessary to calibrate the
analog outputs. Refer to Calibrate the analog outputs on page 70.
Notes:
• The analog outputs are isolated from the other electronics, but are not isolated from each other.
• The analog outputs are self-powered. Do not connect to a load with voltage that is independently applied.
• The analog outputs cannot be used to supply power to a 2-wire (loop-powered) transmitter.
Table 3 Set the analog output
Analog output
0–10 V
4–20 mA with the I- terminal grounded
Connector
CH1
CH2
CH1
CH2
Link
LK5
LK7
LK4
LK8
Connect the optional communications network card
Install the communications card. Refer to the installation instructions supplied with the card.
Connect a remote device to the communications card connector. Refer to Figure 6
on page 15 for
for communication connections.
For RS422 or RS485 communications, install a jumper across pins 2 and 3 on JP1 on the 8001 I/O board.
Configure the communications card. Refer to Configure serial communications on page 41.
Table 4 Communication connections
Pin
L1
L2
L3
L4
RS232
RD
—
TD
—
RS422
RD–A
RD–B
TD–A
TD–B
RS485
D+
D-
—
—
English 19
Pin
L5
L6
Table 4 Communication connections (continued)
RS232
Signal common
Shield
RS422
Network signal common
Shield
RS485
Network signal common
Shield
Connect an optional blowback filter valve
Install a blowback filter valve. Refer to the installation instructions supplied with the blowback filter valve.
Connect the blowback filter valve to the blowback valve connector. Refer to
on page 15.
The blowback valve connector is a relay that supplies 24 VDC (maximum 500 mA) to one valve on an extended blowback filter system. Configure the relay output for separate on and off time intervals.
Refer to
Schedule validations, calibrations and cleaning on page 33.
If more than 500 mA is necessary to operate the blowback valve or more than one blowback valve is necessary, put a power supply between the blowback valve connector and blowback filter valve(s).
Connect optional level detectors
Install up to four level detectors. Refer to the installation instructions supplied with the level detectors.
The optional level detectors give warnings of low reagent levels or a high wastewater level in the drain pan.
Connect the level detectors to the level detector connectors. Refer to
on page 15 and
If a connector is not used, put a jumper on the link for the connector. Refer to Table 5
.
Table 5 Connector and jumper assignments
Level detector
Reagent 1
Reagent 2
Reagent 3
1
Drain pan
1
A third reagent is typically not used.
Connector
REA1
REA2
REA3
REA4
Link
LK10
LK11
LK12
LK13
Plumbing
Make sure to use the size specifications given for tubing. The flow path must increase in diameter as water flows through the system to prevent build-up of backpressure.
Plumbing overview
To keep the environmental rating, make sure that the plumbing ports that are not used are closed.
Tubing and plumbing hardware are supplied by the user.
20 English
Figure 9 Plumbing ports
1 Cleaning solution inlet
2 Sodium persulfate inlet
3 Phosphoric acid inlet
4 Carrier gas inlet
5 Zero standard inlet
6 Span standard/grab sample inlet 11 Sample stream 2 inlet
7 Waste gas vent 12 Optional dual stream inlet block
8 Drain
9 Dilution inlet
10 Sample stream 1 inlet
13 Sample bypass outlet(s)
14 Single stream inlet block
Install the optional dual stream inlet block
Refer to the installation instructions supplied with the dual stream inlet block.
Plumb the drain
D A N G E R
Potential Electrical shock and fire hazards. The drain line must be connected to a drain system that is at ambient pressure.
C A U T I O N
Chemical hazard. If there is a leak in the fluid system, hazardous substances may leak out of the lower enclosure. Put the supplied reagent bottle tray or a bucket under the drain to catch any spills.
C A U T I O N
Chemical exposure hazard. Dispose of chemicals and wastes in accordance with local, regional and national regulations.
1. Remove the drain fitting from the drain under the enclosure.
2. Put the stainless steel pipe through the drain fitting.
3. Install the drain fitting on the drain.
Plumb the sample line and sample bypass
1. Plumb tubing to the sample inlet(s).
English 21
2. Put the tubing in the zero standard container.
3. When the start-up is complete, plumb a sample source to the sample inlet(s) and plumb the
sample bypass outlet(s). Refer to Figure 9
on page 21.
Refer to
Specifications on page 5 for sample requirements.
4. Install a check valve on the sample line near the analyzer so that the sample stream can be stopped for maintenance.
Sample line considerations
Select a good, representative sampling point for the best instrument performance. The sample must be representative of the entire system.
To prevent erratic readings:
• Collect samples from locations that are sufficiently distant from points of chemical additions to the process stream.
• Make sure that the samples are sufficiently mixed.
• Make sure that all chemical reactions are complete.
Connect the sample stream
Install each sample line into a larger process pipe to minimize interference from air bubbles or pipeline bottom sediment. A sample line going into the center of a process pipe is best.
shows examples of good and bad methods of sample line installation into a process pipe.
Keep sample lines as short as possible. Sediment can accumulate in long sample lines.
Sediment absorbs total organic carbon during occurrences of high concentration. Later, total organic carbon dissolves into the sample and causes high readings or longer response times to sample concentration changes.
Figure 10 Sampling methods
1 Air
Plumb the cleaning solution line
2 Sample flow
1. Plumb tubing to the cleaning solution inlet (CLEAN port). Refer to Figure 9
on page 21.
2. Put the tubing in a container of cleaning solution.
Plumb the sample dilution line
Refer to
Figure 16 on page 54 to identify if the analyzer has a dilution pump. If the analyzer has a
dilution pump, plumb the sample dilution line.
1. Plumb tubing to the dilution inlet. Refer to Figure 9 on page 21.
22 English
2. Put the tubing in a container of deionized water.
Plumb the waste gas vent
D A N G E R
Chemical exposure hazard. Inhaled gases from toxic waste can cause death. Plumb the waste gas line to air outside the facility, so that toxic gas does not collect indoors.
W A R N I N G
Potential gas inhalation hazard. The waste gas port must be connected to outside air or a fume hood.
Attach a carrier gas
1. Attach an external source of compressed, CO
2
(Carrier port). Refer to Figure 9
on page 21.
-free air or pure nitrogen to the carrier gas inlet
Do not use oxygen.
Note: As an alternative, a 300 SCF bottle of CO
2 typically supplies gas for 2 to 3 weeks.
free air or nitrogen can be attached. A 300 SCF bottle
2. Install a regulator on the carrier gas line to keep the carrier gas pressure 55 psi or less.
3. Set the carrier gas pressure according to the carrier gas requirements in Specifications
on page 5.
4. Turn the pressure regulator knob in the analyzer until the reading shown on the pressure gauge is
172 kPa (25 psi). Refer to
The pressure regulator knob is behind the sparger manifold.
Figure 11 Front view
1 Sparger manifold
2 Pressure gauge
3 Flow adjustment knob
4 Flow meter
5 Pressure regulator knob
User interface and navigation
User interface
Figure 12 shows the keypad and display. Table 6 gives descriptions of the indicator lights.
English 23
Figure 12 Keypad and front panel display
1 Display
2 Keypad
3 Indicator lights
Light Name
A1 Alarm 1
A2 Alarm 2
F Fault or maintenance event
Table 6 Indicator lights
Description
Illuminates when the TOC (or TC) reading is greater than the limit set for
Alarm level 1.
Illuminates when the TOC (or TC) reading is greater than the limit set for
Alarm level 2.
Illuminates when one or more maintenance event occurs.
Flashes when one or more fault event occurs.
Push one time from the main screen to show the fault or maintenance event(s) that has occurred.
Display description
Refer to
Figure 13 for descriptions of the data shown on the main screen.
When dual stream is selected in the configuration, the main screen shows the selected sample stream for 6 seconds. Then, the stream that is not selected is shown for 3 seconds and the time the stream was last measured.
From the main screen, push to scroll to the Event screen, Status screen and then the Prim v Cal screen.
• Event screen—Shows the fault or maintenance event(s) that has occurred. If there is more than one event, each event is shown for 3 seconds. Push ENTER to clear any latched events that are no longer present.
• Status screen—Refer to
for descriptions of the data shown.
• Prim v Cal screen—Shows the ratio between the current calibration and primary calibration.
Figure 13 Main screen
1 TOC (or TC) reading
2 Analog output range or event code ( Table 7
)
24 English
3 Operating status
4 Time in 24-hour clock format
Table 7 Analog output ranges and event codes
Value Description
Fxx
Mxx
A fault event has occurred. Refer to Fault codes on page 68.
A maintenance event has occurred. Refer to
Figure 14 Status screen
1 Calculated liquid TOC concentration (ug/L or mg/L) 3 Flow cell temperature of the IR detector
2 Rate of change of the current concentration 4 CO
2
concentration in the IR detector (ppm)
Navigation
Use the navigation keys to go to the different screens and menus.
If a key is not pushed within 30 seconds, the display goes back to the main screen. Push ENTER to keep the current screen shown. Push an arrow key to go to another screen or menu.
Table 8 Navigation keys
Key Description
Scroll up the menu or increase the value
ENTER
Ctrl
Ctrl ENTER
Ctrl
Scroll down the menu or decrease the value
Confirm, enter or select
Always used with another key. Push and hold Ctrl before the second key is pushed.
Go up one menu level
Push and hold Ctrl, then push ENTER.
Go to the Service and Setup menus
Push and hold Ctrl, then push .
Security
A passcode must be entered to change some menu functions. A passcode is not necessary to go to any of the screens.
The passcode is 1953. The passcode cannot be changed. Use the arrow keys to select 1953, then push ENTER.
English 25
Startup
Reagent preparation
W A R N I N G
Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled. Refer to the current material safety data sheets (MSDS) for safety protocols.
Reagent preparation guidelines
Atmospheric CO
2
can be absorbed by the reagents and affect results. Obey the guidelines that follow to minimize contamination.
• Use glass containers to mix and store solutions.
• When not in use, fill the empty space in the container with an inert gas and seal the container tightly. Plastic films, such as Parafilm ® , are not sufficient.
• Keep solutions that contain volatile compounds in a refrigerator.
• Keep in mind that basic solutions absorb more CO
2 more CO
2
than hot water.
than acidic solutions. Cold water absorbs
Prepare the acid solution
The phosphoric acid solution removes the inorganic carbon (TIC) from the sample.
1. Add approximately 15 L of DI water to a clean 20-L analyzer container.
2. Find the volume of 85% phosphoric acid (weight %) from
3. Slowly add the phosphoric acid to the container.
4. Dilute with DI water to 20 L.
5. Put the cap on the container and mix.
Note: Measure the sample pH from the drain line and make sure that the sample pH after the acid addition is ≤
3.0. If the pH is > 3.0, increase the concentration of the phosphoric acid until the pH is ≤ 3.0. The pump rate may need to be increased to keep the pH of the sample ≤ 3.0.
Table 9 Preparation for 20 L acid solution, standard units, 30 usage days
10 mg/L (C) TIC removal mL H
3
PO
4
(85%) Molarity
100 mg/L (as C) TIC removal mL H
3
PO
4
(85%) Molarity
Instrument
4195/6195-
1010/3010
1020/3020
1030/3030
2000/4000
2010/4010
1040/3040
1050/3050
1060/3060
1070/3070
2050/4050
2060/4060
2070/4070
2080/4080
mg/L TOC
5
10
25
100
200
50
100
200
500
2000
5000
10,000
20,000
137
68
27
0.1
0.05
0.02
819
410
137
0.6
0.3
0.1
26 English
Table 9 Preparation for 20 L acid solution, standard units, 30 usage days (continued)
Instrument
4195/6195-
2020/4020
2030/4030
2040/4040
mg/L TOC
500
1000
1000
10 mg/L (C) TIC removal mL H
3
PO
4
(85%) Molarity
55
55
0.04
0.04
100 mg/L (as C) TIC removal mL H
3
PO
4
(85%) Molarity
410
137
0.3
0.1
Instrument
4195-
All turbo units
Table 10 Preparation for 20 L acid solution, turbo units, 60 usage days mg/L TOC
All ranges
10 mg/L (C) TIC removal mL H
683
3
PO
4
(85%) Molarity
0.5
20 mg/L (C) TIC removal mL H
1365
3
PO
4
(85%) Molarity
1.0
Prepare the persulfate solution
The sodium persulfate solution oxidizes the organic carbon in the sample.
1. Add approximately 15 L of DI water to a clean 20-L analyzer container.
2. Find the amount of sodium persulfate (MW: 238.10) from
or
.
Note: Use only the molarity of sodium persulfate that is specified for the instrument.
3. Slowly add the sodium persulfate to the container.
4. Dilute with DI water to 20 L.
5. Put the cap on the container and mix until the powder fully dissolves (3 to 5 minutes).
6. Let the container stand until the solution is clear (approximately 30 minutes).
Table 11 Preparation for 20 L persulfate solution, standard units
Sodium persulfate (g)
950
Molarity
0.2
Usage days
90
4195/6195-
1010/3010
1020/3020
1050/3050
1060/3060
1030/3030
1040/3040
1070/3070
2000/4000
2030/4030
2040/4040
2070/4070
2060/4060
2080/4080
2010/4010
2050/4050
2020/4020
mg/L TOC
5
10
100
200
25
50
500
100
1000
1000
10,000
5000
20,000
200
2000
500
1900
2380
2860
3330
4280
5710
6660
7140
7620
0.4
0.5
0.6
0.7
0.9
1.2
1.4
1.5
1.6
90
90
90
30
30
30
30
30
30
English 27
Table 12 Preparation for 20 L persulfate solution, turbo units, 60 usage days
4195-
1006/3006
1002/3002
1005/3005
1007/3007
1008/3008
mg/L TOC
10
2
5
25
50
Sodium persulfate (g)
950
1900
2850
5225
Molarity
0.2
0.4
0.6
1.1
Prepare the zero standard
Use reagent-grade deionized (DI) water, Type I, with less than 50 μg/L TOC for the zero standard.
Put the zero standard in a clean 4-L analyzer container.
Prepare the span standard
Required items:
• Volumetric flask, borosilicate glass (e.g., Pyrex ® ), cleaned with 0.5 M H
3
• Reagent-grade Type I DI water, < 50 µg/L TOC
PO
4
• Organic compound, ACS grade, from Table 13
KHP or ethylene glycol is a suitable span (calibration) standard for most applications. Do not mix two or more standards together.
1. Fill a 1-L volumetric flask ½ full with DI water.
2. Measure the amount of the organic compound from
Note: If more than 1 L of standard is prepared, multiply the value accordingly.
3. Slowly add the organic compound to the flask.
4. Dilute to the mark with DI water and mix fully.
Note: Do not add HCl as a preservative.
5. Put the standard in a clean 4-L analyzer container.
Table 13 Preparation for 1 L span standard
Organic compound
KHP
Ethylene glycol
Ethanol
Methanol
Acetic acid
Sucrose
1,4 Benzoquinone
Urea
Amount for 100 mg/L C
0.212 g
0.233 mL
0.242 mL
0.337 mL
0.250 g
0.238 g
0.150 g
0.500 g
Amount for 1000 mg/L C
2.12 g
2.33 mL
2.42 mL
3.37 mL
2.50 g
2.38 g
1.50 g
5.00 g
28 English
Plumb the reagent solutions
Install the reagent solutions as shown in Figure 15 .
Figure 15 Reagent connections
1 Tubing assembly (4 L)
2 Tubing assembly (19 L)
3 Span solution
4 Zero solution
5 Persulfate solution
6 Acid solution
Turn on the analyzer
Turn on the main AC power to the analyzer.
After a purge, the pumps and UV lamps turn on and the IR detector increases to operating temperature. The analyzer goes online when the IR detector is at operating temperature (50 °C).
After a loss of power or a software reboot, the analyzer turns on and a purge is done before the analyzer goes online. To skip the purge, push ENTER.
Start-up checks
1. When the display shows "Purging", make sure that the analyzer has the correct range for the intended application.
2. Make sure that the sample inlet line(s) is in the zero standard container.
3. Let the analyzer operate for 30 minutes.
4. Look for any leaks in the analyzer. Fix all leaks.
5. Make sure that the reagent weights are at the bottom of the reagent bottles.
6. Make sure that there are no bubbles in the small (
1 manifold. Refer to
/
8
-inch) tubing located to the left of the sparger
Bubbles in the tubing cause a "NO SPARGER FLOW" fault.
7. Make sure that the ½-inch wide vertical chamber located in the sparger manifold is full of bubbles
(TOC analyzers only).
8. Make sure that there are no bubbles in the small (
1 manifold.
/
8
-inch) tubing located in the UV reactor
Bubbles cause a "NO UV FLOW" fault.
English 29
9. Make sure that the bottom of the GLS U-tube is full of liquid and the liquid flows over the U-tube
to the drain. Refer to Figure 2
on page 9.
10. Stop the analyzer. From the main screen, push until "Stop Analyzer" is shown, then push
ENTER.
The UV lamps and pumps turn off.
11. Make sure that the concentration of the carrier gas decreases to less than 20 ppm.
a. From the main screen, push the up arrow two times.
b. Push ENTER to keep the Status screen shown.
The carrier gas concentration (ppm) is shown on the display.
If the carrier gas concentration is greater than 20 ppm, the carrier gas is not good, a leak is present or the IR bench is out of calibration.
If the concentration quickly decreases to 0.0 ppm, the IR bench is out of calibration. Contact the manufacturer for service.
12. To identify a carrier gas leak, do the steps in Identify a carrier gas leak on page 65.
Validate the installation
1. Start the analyzer. From the main screen, push until "Start Analyzer" is shown, then push
ENTER.
The UV lamps and the pumps turn on.
2. Close the enclosure doors.
3. Let the analyzer operate for 1 hour.
4. Do a validation. Refer to
Do a validation manually on page 48.
5. If the mg/L concentration reading is not ±2% of the value of the span calibration standard, go to
Adjust the analyzer on page 30.
6. Connect a sample source(s) to the sample inlet(s) and plumb the sample bypass outlet(s). Refer
to Plumb the sample line and sample bypass on page 21.
Adjust the analyzer
Adjust the analyzer if the analyzer fails the initial validation.
1. Make sure that the zero standard container is plumbed to the ZERO port.
2. Make sure that the span standard container is plumbed to the CALIBRATION port.
3. Put the sample inlet tubing in the span standard container.
4. Make sure that the reading on the flow meter is within the correct range. Refer to
.
5. From the main screen, push the up arrow two times. Push ENTER to keep the Status screen shown.
The CO
2
reading is shown on the display.
6. Turn the flow adjustment knob until the CO
2
reading on the display is the value shown in
for the correct line voltage frequency (50 or 60 Hz). Refer to
7. After 10 minutes, do step 6
again.
Set the carrier gas flow rate to between 30 and 150 cc/minute.
8. Record the value shown on the flow meter for reference during maintenance checks.
9. Make sure that the CO
2
reading stays in this range for a minimum of 5 minutes.
10. Do a primary span calibration.
a. Push the down arrow until "Calibration" is shown, then push ENTER.
b. Push the down arrow until "Primary Span" is shown, then push ENTER.
c. Complete the instructions on the display.
30 English
d. As the span standard has already been measured, push ENTER repeatedly to skip the elapsing time and go to the final screen.
11. Put the sample inlet tubing in the zero standard container.
12. Let the CO
2
reading become stable and become less than 30 ppm.
13. Do a primary zero calibration.
a. Push the down arrow until "Calibration" is shown, then push ENTER.
b. Push the down arrow until "Primary Zero" is shown, then push ENTER.
c. Complete the instructions on the display.
d. As the span standard has already been measured, push ENTER repeatedly to skip the elapsing time and go to the final screen.
14. Connect a sample source(s) to the sample inlet(s) and plumb the sample bypass outlet(s). Refer
to Plumb the sample line and sample bypass
on page 21.
Table 14 Carrier gas flow rates and response times
UV 4195- / 61951010/
3010
55
1020/
3020
110
1030/
3030
170
1040/
3040
160
1050/
3050
125
1060/
3060
150
1070/
3070
175
2000/
4000
70 Reactor carrier
1
(cc/minute)
Sparger carrier
1
(cc/minute)
Response time (minutes)
(T90 at 60 Hz)
CO
2
at span
(ppm)
200
10
950
200
8
950
200
8
950
200
12
950
200
12
950
200
12
950
200
14
950
200
10
9500
1
Flows are approximate at sea level.
UV 4195-
Reactor carrier
1
(cc/minute)
Sparger carrier
1
(cc/minute)
Response time (minutes)
(T90 at 60 Hz)
CO
2
at span at 50 or 60 Hz
(mg/L)
1
Flows are approximate at sea level.
2010/
4010
140
200
10
9500
2020/
4020
165
200
14
2030/
4030
85
200
20
9500 9500
2040/
4040
75
200
13
9500
2050/
4050
150
200
12
2060/
4060
115
200
13
2070/
4070
95
200
16
2080/
4080
120
200
15
9500 9500 9500 9500
English 31
Line voltage frequency
CO
2
at span at 50 Hz
(ppm)
CO
2
at span at 60 Hz
(ppm)
Carrier gas flow rate
1
(cc/minute)
4195-1002/-3002 4195-1005/-3005 4195-1006/-3006 4195-1007/-3007 4195-1008/-3008
300 ±30
380 ±30
80
750 ±30
950 ±30
80
800 ±30
900 ±30
120
3100 ±200
3300 ±200
55
3400 ±200
3600 ±200
100
Select the time, date and language
Select the time, date and language for the display and CSV (comma-separated value) output.
1. Push Ctrl and the down arrow.
The Service screen is shown.
2. Push the up arrow.
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push the up arrow until "Timing" is shown, then push ENTER.
5. Push the up arrow until "Times" is shown, then push ENTER.
6. Push the up arrow until "Time/Date" is shown, then push ENTER.
The Set time screen is shown.
7. Use the arrows to scroll through the time and date screens.
Option
Set time
Set day
Set month
Set year
Date format
Description
Sets the time of day in 24-hour clock format.
Sets the day of the month.
Sets the month of the year.
Sets the year.
Sets the date format—USA (mm/dd/yy) or International (dd/mm/yy).
8. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
9. Use the arrows to change the value, then push ENTER.
10. To change the language:
.
b. Push the up arrow until "Tolerances" is shown, then push ENTER.
c. Push the up arrow until "Language" is shown, then push ENTER.
d. Push ENTER.
Asterisks flash on both sides of the value.
e. Use the arrows to select the language, then push ENTER.
32 English
Operation
Configuration
Select standard or EPA applications
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push until "Application" is shown, then push ENTER.
Asterisks flash on both sides of the value.
5. Use the arrow keys to select Standard or EPA, then push ENTER to save.
When a dual-stream inlet block is used, select EPA.
Do not select USP as USP/EP applications are not supported.
Select the number of sample streams
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push until "Stream" is shown, then push ENTER.
Asterisks flash on both sides of the value.
5. Use the arrow keys to select Single (one stream) or Dual (two streams), then push ENTER to save.
Schedule validations, calibrations and cleaning
Schedule validations, calibrations and cleanings to occur at intervals or daily.
• Intervals—start at a specified time and do again at set time intervals
• Daily—do daily at a specified time on selected days of the week
Schedule blowbacks if a blowback valve is present to clean the sample inlet filter.
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push two times.
"Timing" is shown.
5. Push ENTER.
The first option in the menu is shown, "Times".
6. Push ENTER.
English 33
The first option in the Times menu is shown, "Val time".
7. Use the arrow keys to scroll through the options.
Option
Val time
Cal interval
Description
Sets the start time for validation.
Refer to
Select validation, calibration and cleaning options
on page 34 for more validation configuration.
Sets the time interval between validations.
Val interval
Daily validate
Selects the days of the week on which a validation is done at the Val time. Select Yes or No for each day of the week. Days set to Yes are selected.
The Daily validate values are ignored if the Val interval setting is not zero.
Cal time
Sets the start time for calibration.
Refer to Auto cal options in Select validation, calibration and cleaning options on page 34
for more calibration configuration.
Sets the time interval between calibrations.
Daily calibrate Selects the days of the week on which a calibration is done at the Cal time. Select Yes or
No for each day of the week. Days set to Yes are selected.
The Daily calibrate values are ignored if the Cal interval setting is not zero.
Clean time
Sets the start time for a cleaning.
Refer to Clean options in
Select validation, calibration and cleaning options
on page 34 for more cleaning configuration.
Clean interval Sets the time interval between cleanings.
Daily clean
Selects the days of the week on which a cleaning is done at the Clean time. Select Yes or
No for each day of the week. Days set to Yes are selected.
The Daily clean values are ignored if the Clean interval setting is not zero.
Blowback off
Sets the time interval between blowbacks—0 to 999 minutes. Set to 0 to disable blowback function.
The blowback valve pushes compressed air back through the sample inlet filter to remove any debris that has collected.
The blowback off and on settings only apply if a blowback valve is used.
Blowback on
Sets the time interval that compressed air is blown back through the sample inlet filter—0 to
100 seconds.
8. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
9. Use the arrow keys to change the value, then push ENTER to save.
Select validation, calibration and cleaning options
D A N G E R
Chemical hazard. Make sure to keep the UV lamps off during cleaning if the cleaning solution can react with UV light and produce harmful gases.
Select the auto validation, auto calibration and auto cleaning options.
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
34 English
The first option in the Setup menu is shown, "Level Criteria".
4. Push .
"Auto Options" is shown.
5. Push ENTER.
The first option in the menu is shown, "Cal after val".
6. Use the arrow keys to scroll through the options.
Option
Cal after val
Validation tol
Description
Enables or disables a calibration to be done automatically after an auto validation fails.
Push Enter to select Yes or No. The change is saved when the screen is exited.
Sets the validation tolerance (%).
If the validation result (%) is different by more than the validation tolerance, the analyzer fails validation.
Spill threshold
Sets the spill threshold (%).
If the TOC level is greater than the spill threshold, a cleaning cycle is done for the spill recovery time. After the cleaning cycle, a purge cycle is done, then the analyzer goes online to measure the other sample stream. This lets the analyzer go back to online status as soon as the spill is fixed.
Spill recovery
Clean options
Sets the spill recovery time—0 to 99 minutes.
The spill recovery is the time period that the analyzer stays offline until a spill, as identified by the spill threshold, is fixed.
Sets two cleaning options. Push Enter, then select Yes or No for each option.
• Clean with lamps on—Always set to No. Refer to danger statement.
• Clean before cal—Set to Yes recommended. When set to Yes, a cleaning is always be done before an auto calibration.
Auto cal options
Push Enter to select Yes or No. The change is saved when the screen is exited.
Sets what calibration adjustments are done when an auto calibration is done—zero only, span only or zero and span.
7. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
8. Use the arrow keys to change the value, then push ENTER to save.
Select the amount of time for analyzer phases
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push two times.
"Timing" is shown.
5. Push ENTER.
The first option in the menu is shown, "Times".
6. Push .
"Periods" is shown.
7. Push ENTER.
The first option in the Periods menu is shown, "Pre zero period".
English 35
8. Use the arrow keys to scroll through the options.
Option Description
Pre zero period
Sets the amount of time the analyzer is switched to the Zero standard inlet (Zero port) before a zero baseline is started—1 to 60 minutes.
Pre span period
Sets the amount of time the analyzer is switched to the Span standard inlet (Calibration port) before an auto span calibration is started—1 to 60 minutes.
Clean period
Sets the amount of time the analyzer is cleaned during an auto cleaning (or auto calibration mode if enabled during an auto calibration)—1 to 60 minutes.
Purge period
Sets the amount of time of a purge cycle—2 to 60 minutes.
A purge cycle removes any liquid from the analytical system before that analyzer is put online.
A purge is done after a calibration or validation, auto cleaning or a single (grab) sample analysis.
Stream 1 period
1
Stream 2 period
1
Sets the amount of time the analyzer measures sample stream 1—0 to 999 minutes.
Select 0 to stop measurements on sample stream 1.
Note: The stream period 1 and 2 do not include the purge period.
Sets the amount of time the analyzer measures sample stream 2—0 to 999 minutes.
Select 0 to stop measurements on sample stream 2.
1
Only available when a dual stream analyzer is selected.
9. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
10. Use the arrow keys to change the value, then push ENTER to save.
Select the level criteria for alarms and analog output ranges
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push ENTER.
The first option in the menu is shown, "Alarm level 1".
5. Use the arrow keys to scroll through the options.
Option
Alarm level 1
Alarm level 2
Inhibit level
Description
Sets the Alarm level 1 setpoint.
When the TOC (or TC) reading is greater than the Alarm level 1 setpoint, Alarm level 1 is active.
Alarm level 1 and 2 are rising level, unlatched alarms.
Sets the Alarm level 2 setpoint.
When the TOC (or TC) reading is greater than the Alarm level 2 setpoint, Alarm level 2 is active.
Sets the inhibit level setpoint.
The inhibit level is a TOC percentage of the full scale range of the analyzer. To disable this feature, enter 0%.
If the inhibit level setpoint is exceeded at the time of a scheduled calibration, validation or cleaning, the calibration, validation or cleaning cycle does not occur.
Use this feature to continue monitoring a high carbon concentration even if a calibration, validation or cleaning is scheduled.
36 English
Option
Range
Change
Range
Select
Description
Sets the Range Change percentage. The Range Change percentage only applies when Range
Select is set to Auto ranging.
Note: The term range in this section applies only to the analog output range and not to the actual TOC range of the analyzer.
When the TOC reading increases, the analog output range goes up one level (e.g., R1 to R2) when the TOC reading is the range change percentage of the current analog output range. For example, if the Range Change is 90% and the analog output range is 0 to 1000 ug/L, the analog output range changes up when the TOC reading is 900 ug/L (90% of 1000) or more.
When the TOC reading decreases, the analog output range goes down one level (e.g., R2 to
R1) when the TOC reading is the Range Change percentage minus 5% of the analog output range that is the next level down. For example, if the Range Change is 90% and the analog output range of the next level down is 0 to 1000 ug/L, the analog output range changes down when the TOC reading is 850 ug/L (85% of 1000) or less.
Sets the analog output range (R1–R4) for the two analog outputs (CH1 and CH2)—Fixed range or Auto range.
Fixed range—Typically used. The analog output range stays in the selected range (e.g., R4).
The other three ranges are not used (e.g., R1, R2 and R3). The main screen shows the current analog output range.
Auto range—Not typically used. The selected analog output range automatically changes between R1, R2, R3 and R4 based on the current TOC (or TC) reading and Range Change setting.
If Auto range is selected, set one of the analog outputs to Range ID and the other to one of the
TOC reading options (Live mg/L, Zero mg/L or Latched mg/L) to identify the TOC reading. Refer to
Set a condition to each the analog output on page 37.
To calculate the TOC reading using the current values (4-20 mA) on the two analog outputs:
1. Use the Range ID value (mA) to identify the current analog output range (i.e. R1 or R4).
Refer to Set a condition to each the analog output
on page 37.
2. Identify the TOC reading range (i.e. 0 to 2,000 ug/L) of the current analog output range.
Refer to Output Ranges.
3. Divide the TOC reading range (i.e. 2,000 ug/L) by 16 mA. 16 mA is the difference between
20 mA and 4 mA.
4. Subtract the current value of the analog output that is set to a TOC reading (i.e. 12 mA) from 20 mA.
5. Multiple the two results to get the TOC reading.
Output
Ranges
For example, CH1 is set to the Range ID and is at 4 mA = R1. CH2 is set to a TOC reading and is at 12 mA.
If R1 is 0 to 2,000 ug/L, divide 2000 by 16. Then, multiply the result by 12 mA. The result is
1000 ug/L.
Sets the TOC ranges of the four analog output ranges (e.g., 0 to 1000 ug/L)—Output range
1 (R1), Output range 2 (R2), Output range 3 (R3) and Output range 4 (R4).
The TOC ranges cannot be greater than the range of the analyzer. Make sure that the TOC range increases from R1 to R4.
6. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
7. Use the arrow keys to change the value, then push ENTER.
Set a condition to each relay and analog output
Set a condition to each the analog output
When one or both analog output connectors are used, set the analog output connector(s) that is used
to an analyzer condition or reading to. Refer to Connect the analog outputs (optional)
on page 19.
1. Push Ctrl .
The Service screen is shown.
English 37
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push until "Mapping" is shown.
5. Push ENTER.
The first option in the Mapping menu is shown, "Map Analogs".
6. Push ENTER.
The first option in the Map Analogs menu is shown, "CH1".
7. Use the arrow keys to scroll through the options.
Option
Slope
Description
Sets the current value (4-20 mA) at the analog output to change linearly according to the rate of change of the current concentration (mg/L per second). A change of ±1 results in a
±0.016 mA change in the current value.
The rate of change range is -500 to +500. When the rate of change is -500, the current value is 4 mA. When the rate of change is 0, the current value is 12 mA. When the rate of change is 500, the current value is 20 mA.
Temperature
Sets the current value (4-20 mA) at the analog output to change linearly according to the temperature of the IR detector flow cell. A change of ±1 °C results in a ±0.16 mA change in the current value.
The temperature range is 0 to 100 °C (32 to 122 °F).
0 °C (32 °F) = 4 mA, 50 °C (122 °F) = 12 mA, 100 °C (212 °F) = 20 mA
Live mg/L
Gas ppm
Sets the current value (4-20 mA) at the analog output to change linearly according to the
TOC (or TC) reading, even when the analyzer is offline (e.g., during a purge, cleaning or calibration).
The TOC range is the current analog output range (Rx), which is shown on the main screen and selected by the user. Refer to Select range in
Select the level criteria for alarms and analog output ranges
on page 36.
Sets the current value (4-20 mA) at the analog output to change linearly according to the
CO
2
concentration in the IR detector (ppm).
The concentration range is from zero to full scale (1,000 or 10,000 ppm).
Zero mg/L
Sets the current value (4-20 mA) at the analog output to change linearly according to the
TOC (or TC) reading when the analyzer is online. The analog output is 0 mA when the analyzer is offline.
The TOC range is the current analog output range (Rx), which is shown on the main screen and selected by the user. Refer to Select range in
Select the level criteria for alarms and analog output ranges
on page 36.
Latched mg/L Sets the current value (4-20 mA) at the analog output to change linearly according to the
TOC (or TC) reading and holds the last valid online reading when the analyzer is taken offline.
The TOC range is the current analog output range (Rx), which is shown on the main screen and selected by the user. Refer to Select range in
Select the level criteria for alarms and analog output ranges
on page 36.
Fault ID
Sets the current value (4-20 mA) at the analog output to change according to the operating status of the analyzer.
Online = 4 mA, Out of service (offline) = 8 mA, Maintenance event = 12 mA and Fault event
= 16 mA
Range ID
Sets the current value (4-20 mA) at the analog output to change according to the selected analog output range (R1–R4). Only set the analog output to Range ID if the analog output
R1 = 4 mA, R2 = 8 mA, R3 = 12 mA and R4 = 16 mA
For example: If R2 is the current analog output range, the current value on the analog output is 8 mA.
38 English
8. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
9. Use the arrow keys to change the value, then push ENTER to save.
10. Push .
"CH2" is shown.
11. Do steps
–
Set a condition to each analog output for the EPA
For EPA drinking water applications, map the analog outputs to:
• CH 1—Latched mg/L 1 (Stream 1)
• CH 2—REM % (Stream 2)
In EPA mode, the stream number is added to the TOC mg/L options (e.g., Latched mg/L 1 and
Latched mg/L 2) and REM % is available as an option.
Set a condition to each output relay
When one or more relay connectors are used (S1–S5), set the relay connector(s) to an analyzer
event or status. Refer to Connect the relays (optional) on page 17.
Each relay may be selected as normally energized or normally de-energized. For example, if relay
S1 is set to Alarm 1 and selected as energized, the relay coil is energized when Alarm 1 occurs.
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push until "Mapping" is shown.
5. Push ENTER.
The first option in the Mapping menu is shown, "Map Analogs".
6. Push until "Map Relays" is shown.
7. Push ENTER.
The first option in the Map Relays menu is shown, "Relay S1".
8. Use the arrow keys to scroll through the options.
Option
Alarm 1
Alarm 2
Online
Offline
Description
Sets the relay to Alarm 1.
Alarm 1 and Alarm 2 are rising level, unlatched alarms.
Sets the relay to Alarm 1.
Sets the relay to the online operating status.
The online operating status indicates that the analog outputs are representative of the current
TOC reading.
When set to a relay, the online status lets DCS systems know when the analog output is representative of the current TOC reading. This is necessary because if the analyzer is not currently measuring the sample stream, the analog output may be latched to the last valid
TOC reading when it was measuring the sample. The online relay will not be in its TRUE status during this time. Also, when the analog output has been set to Live mg/L, the output will reflect whatever is being measured.
Sets the relay to the offline operating status.
Note: The analyzer is offline during warm up, when in the service menu, during a purge, cleaning, calibration or validation cycle or when a grab sample is measured.
English 39
Option
Fault
Description
Maintenance Sets the relay to maintenance events.
The relay is active when any of the maintenance events occur.
Sets the relay to fault events.
The relay is active when any of the fault events occur.
Stream 1
Sample
Mxx
Sets the relay to Stream 1.
The relay is active when Stream 1 is selected.
Note: On available on dual stream analyzers.
Sets the relay to a true or false sample.
True sample— when the analyzer is any phase of measurement of a true sample, including a purge phase.
False sample— when in any phase of cleaning, calibration, validation or grab sample measurement, or when the analyzer is offline.
Sets the relay to an individual maintenance event—M05, M06, M07, M09 or M11.
Fxx
Sets the relay to an individual fault event—F01, F02, F03 or F04.
9. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
10. Use the arrow keys to change the value, then push ENTER to save.
11. When "Sx Energized?" is shown, select Yes or No. To change the value, do steps 9
–
.
When main power to the analyzer is off, a normally energized relay indicates the condition (e.g.
Alarm 1 or Online).
An illuminated LED indicates an energized relay. In either condition (energized or de-energized), both normally open and normally closed contacts are available.
12. Push .
"Relay S2" is shown.
–
again until all the relay connectors used are configured.
Set a condition to each output relay for the EPA
For EPA use with drinking water analyzers, set a relay(s) to the EPA P/F option.
In EPA mode, relays can be set to EPA P/F (pass/fail criteria).
The relay holds the pass/fail criteria even when the analyzer is offline.
Set a condition to the input relay
When the input relay connectors is used (SW1), set the relay connector to an analyzer condition.
Refer to
on page 17.
Close or open the contacts of the input relay for 3 seconds to toggle the analyzer condition from one condition to the other. The condition can only be toggled back after 3 seconds. To enable this function, enable SW1 in the Service menu. Refer to
Change the input status on page 70.
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push until "Mapping" is shown.
5. Push ENTER.
The first option in the Mapping menu is shown, "Map Analogs".
6. Push until "Map Relays" is shown.
40 English
7. Push ENTER.
The first option in the Map Relays menu is shown, "Relay S1".
8. Push until "?" is shown, then push ENTER.
9. Use the arrow keys to scroll through the options.
Option
Start/Stop
Auto clean
Auto val
Auto cal
Toggle stream
1
STR1 latched
STR2 latched
1
1
Description
Sets the relay to start the analyzer (close contacts) or stop the analyzer (open contacts).
Sets the relay to start an auto cleaning (close contacts). The analyzer goes back online when the cleaning is done.
Sets the relay to start an auto validation (close contacts). The analyzer goes back online when the calibration is done.
Sets the relay to start an auto validation (close contacts). The analyzer goes back online when the validation is done.
Sets the relay to toggle the selected stream from the stream that is not currently selected
(close contacts) to the previously selected stream (open contacts).
Sets the relay to keep Stream 1 selected (close contacts) or let the analyzer select the stream (open contacts).
Sets the relay to keep Stream 2 selected (close contacts) or let the analyzer select the stream (open contacts).
1
Dual stream analyzer only.
10. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
11. Use the arrow keys to change the value, then push ENTER to save.
Configure serial communications
If the optional communication card is installed, select the serial communications protocol and protocol settings.
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push until "Serial" is shown.
5. Push ENTER.
The first option in the Serial menu is shown, "Protocol".
6. Use the arrow keys to scroll through the options.
Option
Protocol
Description
Sets the communications protocol—CSV, X3.28, 8811 or Modbus RTU.
CSV—outputs data logging and comma separated values. CVS protocol is used for monitoring
and
on page 85.
X3.28—for Manufacturer Service Representative use only.
8811—for connection to an 8811 multi-stream sequencer
Modbus RTU—Industrial Standard Protocol. For more information about the Modbus Protocol, go to the Schneider Automation website at www.modicon.com and/or order the Modicon
Modbus Protocol Reference Guide from Modicon (part number PI-MBUS-300).
English 41
Option
Address
Description
CSV period
Sets the time in seconds between the output of CSV data from the serial port—2 to
3600 seconds. This option is only available when CSV is selected for protocol.
Sets a multidrop address for the analyzer. This option is only available when X3.28 or Modbus
RTU is selected for protocol.
Each analyzer must have a different address. If no multidrop addressing is used, set to 0.
Float format Sets the word order used by Modbus to represent real numbers (floating point numbers). This option is only available when Modbus RTU is selected for protocol.
7. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
8. Use the arrow keys to change the value, then push ENTER to save.
Table 15 Communication settings
Baud
9600
Parity
none
Number of data bits
8
Stop bit
1
Change the tolerance settings (not recommended)
N O T I C E
The tolerance settings affect analyzer performance. The manufacturer recommends that tolerance settings not be changed from the factory settings.
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push until "Tolerances" is shown.
5. Push ENTER.
The first option in the Series menu is shown, "Zero tolerance".
6. Use the arrow keys to scroll through the options.
Option Description
Zero tolerance
Sets the permitted CO
2
ppm variation (±) for an auto zero calibration.
Span tolerance
Sets the permitted CO
2
ppm variation (±) for an auto span calibration.
Maint % Primary Sets the Maint % Primary percentage.
If the difference between the current calibration and the primary calibration is more than the Maint % Primary percentage, a maintenance event occurs.
Fault % Primary Sets the Fault % Primary percentage.
If the difference between the current calibration and the primary calibration is more than the Fault % Primary percentage, a fault event occurs.
Averaging
Sets the numbers of sample readings that are used to calculate the moving average reading—low, medium, high, very high or adaptive. Adaptive is the recommended setting.
.
The Averaging setting is selected on the IR gas averaging screen, which is shown after the passcode is entered.
42 English
Option Description
Maint Pressure
Sets the maintenance event threshold for UV reactor pressure.
If the UV reactor pressure is greater than the Maint Pressure value, a maintenance event occurs.
Fault Pressure
Sets the fault event threshold for UV reactor pressure.
If the UV reactor pressure is greater than the Fault Pressure value, a fault event occurs.
Note: A pressure sensor measures the pressure at the UV reactor manifold. When the pressure increases to greater than the threshold pressure, the analyzer automatically stops the pumps to prevent damage to the carrier gas system caused by the corrosive liquids in the analyzer.
7. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
8. Use the arrow keys to change the value, then push ENTER to save.
Table 16 Averaging options
Option
Low
Medium
High
Very high
Adaptive
Sampling mode
4 samples every 2 seconds
20 samples every 10 seconds
40 samples every 20 seconds
80 samples every 40 seconds
Adaptive filter
Change model and range
N O T I C E
When the model and range are changed, all user-entered setting and calibration values are set to the factory defaults.
Before the model and range are changed, record:
• All user-selected settings
• The zero and span values for the two analog outputs (CH1 and CH2)
The zero and span values for the analog outputs are recorded on the Output Adjust screens in the
Service menu.
1. Push Ctrl .
The Service screen is shown.
2. Push .
The Setup screen is shown.
3. Push ENTER.
The first option in the Setup menu is shown, "Level Criteria".
4. Push until "Analyzer" is shown, then push ENTER.
Asterisks flash on both sides of the value.
5. Use the arrow keys select the model number and unit of measure, then push ENTER to save.
6. After the automatic reboot, enter the recorded zero and span values for CH1 and CH2 in Output
Adjust in the Service menu.
Typically when a different analyzer is selected, it is necessary to configure the hardware again. Refer
on page 83.
English 43
Calibration
Calibration overview and options
Note: In this manual, TOC is expressed in µg/L while CO
2
concentrations are expressed in ppm.
The analyzer supports primary, manual, automatic and multi-point calibration.
Primary and manual calibrations are identical in operation. Do a primary calibration after a new peristaltic tube or lamp has been installed.
The three forms of multi-point calibrations are detailed in the Multi-point Calibrations section of this manual.
The analyzer is calibrated by measuring and storing the CO
2
gas ppm produced by at least two known TOC standards. A calibration set may be represented by at least two points on a graph of ppm CO
2
versus a zero and a span (µ/L TOC) so that a straight line interpolation and extrapolation can be done between the points. The lower point is defined by the gas ppm x
1 water is applied to the analyzer. This defines the point (0, y
1 point (x
2
, y x
produced when DI
) and is called the baseline. The higher
) is the span reading, though it is not always done at the full scale of the analyzer.
The slope of the interpolated/extrapolated line is the gain of the analyzer in ppm/µ/L (gas/TOC).
Refer to Figure XX. The slope is given by the equation:
Gain = y
2
-y
1
/x
2
For example, if a 0-1000 µ/L analyzer is calibrated with 800 µ/L, the calibration is defined as (0,25) and (800, 7602). This gives a gain of (7602-25)/800, i.e., 9.475 ppm/µ/L. The gain of each analyzer slowly varies with time as the peristaltic pump tubing and the UV lamps get older. Following any manual calibration or auto-calibration, this aging can be identified by the % in the Pri v cal screen. An online TOC measurement of a sample is produced by measuring the CO
2
gas ppm and using the straight line to mathematically look up the TOC µ/L. If the calibration set (0, y
1 as the two point active calibration.
) and (x
2
, y
2
) are used
Online sample TOC (mg/L) = (y x
-y
1
) * x
2
/(y
2
- y
1
) where y s
is the CO
2
ppm produced by the sample.
At any point in time, four distinct calibrations are stored separately in the analyzer database. Only one calibration is used at any time to calculate the online TOC µ/L.
The primary, manual and auto calibrations are two point calibrations as described above. Minor variations of the data points will exist due to tolerances. These calibrations should yield the same gain (slope).
The fourth calibration is a multiple point calibration that uses measurements of CO
2 more than two standards, one of them always being the zero.
produced by
Primary and Manual calibration
Primary and Manual Calibration are identical supervised calibrations that are run by the operator.
The distinction between the two is that a primary calibration should be performed only after the peristaltic or lamp has been replaced, when the analyzer will have the best performance and theoretical gain. A successful primary calibration will automatically update the manual calibration data set as well as the primary calibration data set.
Auto calibration
This scheduled calibration sequence is automatically carried out by the analyzer. Zero and span standards are automatically drawn from the ports as required, to determine the auto-calibration data set. A successful auto-calibration will become the active calibration.
Active calibration
This is the calibration data set used to calculate the TOC during an online TOC measurement. The primary, manual, autocalibration or multipoint calibration may be manually set to be the active calibration.
The successful completion of any type of calibration will result in that calibration being used as the active calibration and the entry in the Manual Control/Active Cal screen will be changed to reflect the type of calibration just completed.
44 English
Active versus primary calibration % (Prim v cal)
This is the ratio of the gains of the active calibration set to the gain of the primary calibration set expressed as a percentage. The deviation from 100% will identify the change in the analyzer gain.
If the active calibration set gain g a
= (y
2a
- y
1a
)/x
2a is compared to the primary gain g p
= (y
2p
- y
1p
)/x
2p as a percentage, the result is
100*g a
/g p
= 100 * x
2p
* (y
2a
- y
1a
)/x
2a
* y
2p
- y
1p
)
After a primary calibration, this percentage will always be 100% because the active calibration is the primary calibration. If manual calibration is selected, it will still be 100% as the primary calibration copies to the manual calibration set. Only following the next calibration will the result be different.
Thus a relative percent degradation of the performance can be determined and maintenance or fault events flagged to the operator. See Figure XX.
Calibration screen
Push ENTER while in the Calibration screen to display the calibration data set in use. When one of the three multi-point calibrations is selected, the screen shows the type of calibration and scrolls through each of the calibration points in use. An example follows of information that a screen might show.
Calibration
0 µg/l 1000 µg/l
19 ppm 950 ppm
The two gas ppm values shown are the current readings for zero (19 ppm) and span (950 ppm).
Push ENTER again to select the calibration options.
Manual zero calibration
Push ENTER while in the Calibration menu. The first submenu in the Calibration menu is the Manual zero menu. The information in bold appears on the display screen.
Manual Zero
1. Push ENTER to select Manual Zero and move to a prompt screen.
2. Push ENTER. The screen shows the apparent TOC using the prior calibration, the pre zero countdown timer from the pre zero period, and the prior zero TOC µg/L.
20 µg/l 285s
Last 0.0 µg/l
3. Push the up arrow to display the equivalent screen displaying ppm CO
2
20 ppm STAB
instead of µg/L TOC.
Last 17 ppm
4. Push ENTER. This selects valves V1 and V2 and places the analyzer in an offline status, drawing water from the zero inlet port. The display changes, as shown.
20 ppm 295s
Last 17 ppm
• 20 ppm is the current gas CO
2
ppm in the current calibration.
• 295s is the current seconds in the countdown (from the pre-zero period).
• Last 17 ppm is the prior calibration zero water gas CO
2
ppm.
5. After the pre-zero period, the analyzer shows the CO2 gas reading and a message indicating whether or not the reading is stable. Push ENTER to move to the next screen. The analyzer automatically detects the criteria for stability and shows STAB. However, the user is responsible for determining that the zero is sufficiently stable to proceed. A longer exposure to DI water creates a better zero calibration. This is especially true when the analyzer has been exposed to high concentrations of TOC immediately prior to gas calibration.
English 45
6. When the ppm CO
2
or µg/L TOC reading becomes stable, push ENTER to lock the signal in the analyzer and show a fixed screen that shows the live ppm CO
2 reading.
2 reading and prior zero ppm CO
7. Push CTRL then ENTER to go back to the prior screen and allow repeated update of the zero. A manual zero will automatically result in the active calibration being a manual calibration.
Manual Span Calibration
Push the up arrow from the Manual zero menu to enter the Manual Span calibration menu.
Note: The span value is not necessarily the full scale span, but is the value of the span calibration standard. The displayed values (in ppm, µg/L and mg/L) may not match your analyzer.
1. Push ENTER to select Manual Span and proceed to the calibration standard value screen.
2. Push ENTER to progress to the prompt screen to make sure the standard is connected to the calibration port.
3. Push ENTER. The screen shows the apparent TOC using the prior calibration, the pre span countdown timer, and the prior span TOC µg/L.
Push the up arrow to display the equivalent screen displaying ppm CO
2
instead of µg/L TOC.
4. After the pre span countdown is completed, the analyzer displays the TOC µg/L reading and prompts to push the ENTER button when stable.
For accurate calibration, high range analyzers benefit from long exposure to the span standard.
The stability is tested before determining the result. However, the user is responsible for determining when the reading is stable. During this period, push ENTER to progress to the next screen.
5. Push ENTER to store the result of the calibration in the analyzer data base. A comparison screen between the live ppm and the span ppm results.
At this point the manual calibration is made the active calibration, i.e., Cal to use is set to Manual.
6. Push ENTER to produce a final screen that displays the comparison of the calibration set with the primary calibration data set.
Primary Zero/Primary Span Calibration
Perform a primary zero and primary span calibration only when the pump tubing and/or lamp has been replaced. This allows progressive degradation of the tubes and lamps to be monitored.
A primary zero and primary span calibration follows a similar sequence of menu prompted operations as were displayed during manual zero and manual span calibration.
The difference between the two calibrations (Manual zero/Manual span and Primary zero/Primary span) is that the calibration set obtained during Primary zero/Primary span calibration is copied to two locations, while Manual zero/Manual span calibration set is copied to only one location.
Immediately following a primary zero or primary span calibration, the primary calibration is made the active calibration, i.e., Manual Control/Active Cal is set to Primary.
Autocal Standard Screen
The value shown on the Autocal Standard screen is the concentration of the standard that will be supplied to the calibration port and used during an auto calibration and auto validation.
The concentration value on the screen may be changed as follows:
1. Push ENTER.
2. Flashing asterisks will appear on either side of the displayed value. Use the up or down arrow to change the value.
3. Push ENTER when the desired value is displayed to enter the value in memory.
Multi-point calibrations
These are operator supervised calibrations using between 2 and 10 non-zero TOC standards.
The Multi-point add, Multi-point delete, Multi-point update, and Multi-point zero operations are used to perform the Multi-point calibration.
46 English
There is only one set of multi-point calibration data. The way the calibration data is used during an online measurement is different for each of the options selected in the Manual control/Active cal selection screen.
The multi-point calibration data set consists of a zero point (0,y calibration span points, (x
2,
,y
2
), (x
3
,y
3
)......... (x
11
,y
11
1
) and up to ten non zero µg/L
). Menu entries are provided to add points, delete points, update points. The initial default entries in the multi-point calibration set are 0%, 10%, 25%,
50% and 100% of the full scale of the analyzer. For example, for the 1000 µg/L unit the points are
(0,y
1
), (100,y
2
), (250,y
3
), (500,y
4
), (1000,y
5
). The y n
gas CO
2
values are by default automatically chosen to define a perfectly linear graph. If a multi-point calibration set is selected as the active calibration, either manually or by performing any multi-point calibration, the Pri v Cal screen will only reflect the calculation based on the most recent calibration point measured and the multipoint zero.
Segmented
When this option is selected, the multi-point zero and the non zero multi-point standards will be used to calculate the TOC using a piece point linear representation.
TOC added
If the standards used for the TOC added calibration are analyzed after the calibration online, the
TOC reported will be offset by the reagent water blank.
When this option is selected, the multi-point zero is not used. Only the non zero TOC calibration points are used to calculate the best-fit straight line calibration.
This line is used to calculate the reagent water blank and its associated ppm CO
2
value. A TOC added calibration is useful when calibrating a low range analyzer when the unknown carbon impurity in the DI water is significant.
Fitted
When this option is selected the multi-point zero and the multi-point TOC standards will be used to calculate the TOC using the best-fit straight-line calibration.
Multi-point add
For a point to be added to a multi-point calibration, the TOC standard must be specified and a calibration performed with this standard to get the corresponding CO
2
gas concentration. This procedure is similar to a manual calibration, except that the display returns to the edit µg/L screen.
This way, after the initial point has been added, subsequent points may be entered. A new TOC value must not duplicate an existing entry and be at least 10% different from an existing entry. Points may be entered in any order. Following a successful calibration of a point, the entry is added to the calibration set and ordered from low to high.
Multi-point delete
A calibration point in the multi-point calibration set may be deleted. This is useful if the calibration point is bad or no longer required and the user does not wish to update the calibration point.
Passcode entry is required to prevent inadvertent deletion. It is not possible to delete the last two points in the set or the zero point as a zero and span must always be retained.
Multi-point update
This procedure allows the re-calibration of existing calibration points. The screen sequence is similar to the manual calibration.
Multi-point zero
This procedure allows the zero in the multi-point calibration set to be established for segmented and fitted Active Cal selections. The screen sequence is similar to the manual zero procedure.
Validation
Do a validation to identify the validity of the current calibration.
on page 33 to schedule auto validations.
Show the results of the previous validation
1. Push until "Validation" is shown, then push Enter.
English 47
"Standard Validation" is shown.
2. Push Enter.
The results of the previous validation are shown. The display alternately shows the:
• TOC reading in mg/L
• TOC reading as a percentage of the TOC standard
Do a validation manually
1. Push until "Validation" is shown, then push Enter.
"Standard Validation" is shown.
2. Push Enter.
The results of the previous validation are shown. The display alternately shows the:
• TOC reading in mg/L
• TOC reading as a percentage of the TOC standard
3. Push Enter to do a validation.
The TOC standard that was used for the previous validation is shown.
4. To change the TOC standard for validation:
a. Use the arrow keys to change the value.
b. Push Enter to save the value.
5. Push Enter.
6. Make sure that the span (TOC) standard container is plumbed to the CALIBRATION port.
7. Push Enter.
The time that remains to complete the validation is shown. When the validation is complete, the display alternately shows the:
• TOC reading in mg/L
• TOC reading as a percentage of the TOC standard
Manual control
Use the manual control menu to:
• Start, stop or prevent an auto validation, calibration or cleaning
• Select one of the six calibrations to use as the basis for calculation of TOC (or TC)
• Reboot the analyzer
• Change the stream selected on a dual stream analyzer
1. Push until "Manual control" is shown, then push Enter.
The first option in the Manual control menu is shown, "Initiate cln?".
2. Use the arrow keys to scroll through the options.
Option
Initiate cln?
Initiate cal?
Initiate val?
Go online?
Inhibit next clean?
Description
Starts a cleaning.
Starts an auto calibration.
Starts an auto validation.
Stops a validation, calibration or cleaning cycle that is in progress and puts the system online.
Prevents the occurance of the next scheduled auto cleaning, but no subsequent auto cleanings.
48 English
Option
Inhibit next calibration?
Inhibit next validation?
Active Cal
Reboot system
Change to
1
Description
Prevents the occurance of the next scheduled auto calibration, but no subsequent auto calibrations.
Prevents the occurance of the next scheduled auto validation, but no subsequent auto validations.
Sets the calibration that is used as the basis for the calculation of TOC (or TC)—
Manual, Primary, Auto-cal, Segmented, TOC added or Fitted.
Refer to Calibration overview and options on page 44.
Push Enter to change the value on the screen. Use the arrow keys to change the value, then push Enter to save.
Turns the analyzer off and back on. The previous settings are kept.
Sets the selected stream—Stream 1 or Stream 2.
Push Enter to change the value on the screen. Use the arrow keys to change the value, then push Enter to save.
The amount of time the analyzer measures the selected sample stream is in
accordance with the Stream period setting. Refer to Select the amount of time for analyzer phases
on page 35.
1
Dual stream analyzer only.
3. Push Enter to select the option.
Measure a grab sample
The analyzer automatically goes offline when a grab sample is measured and then back online after measurement.
1. Push until "Grab Sample" is shown, then push Enter.
The results of the previous grab sample measurement are shown.
Note: Grab sample readings are only shown on the Grab sample screen.
2. Disconnect the tubing for the span standard container from the span standard/grab sample inlet
(CALIBRATION port). Refer to
3. Plumb clean tubing to the CALIBRATION port, then put the tubing in the grab sample.
4. Push Enter.
5. Push Enter again to start the measurement.
The time to complete the measurement is shown. The time is according to the Pre span period setting.
When the measurement is completed, the reading and the time and date of the measurement are shown on the grab sample screen for 10 seconds.
6. Disconnect the tubing from the CALIBRATION port.
7. Plumb the span standard container to the CALIBRATION port.
Maintenance
D A N G E R
Multiple hazards. Only qualified personnel must conduct the tasks described in this section of the document.
C A U T I O N
Ozone inhalation hazard. Under certain conditions, this instrument produces ozone concentrations above safe exposure limits. Plumb waste gases to a fume hood or to the building exterior in accordance with local, regional and national requirements.
English 49
If loss of liquid sample occurs and the UV lamps remain on, the interior analyzer and the waste gas line may have ozone concentrations at levels greater than 200 ppm. This ozone level is well in excess of permissible occupational exposure limits. When opening either the upper or lower cabinets, allow 60 seconds for any potential ozone gas build-up to dissipate before working on the instrument.
Note: The manufacturer is not responsible for damage to the instrument caused by failure of the user to do recommended periodic maintenance.
Electrostatic discharge (ESD) considerations
N O T I C E
Potential Instrument Damage. Delicate internal electronic components can be damaged by static electricity, resulting in degraded performance or eventual failure.
Refer to the steps in this procedure to prevent ESD damage to the instrument:
• Touch an earth-grounded metal surface such as the chassis of an instrument, a metal conduit or pipe to discharge static electricity from the body.
• Avoid excessive movement. Transport static-sensitive components in anti-static containers or packages.
• Wear a wrist strap connected by a wire to earth ground.
• Work in a static-safe area with anti-static floor pads and work bench pads.
Maintenance schedule
gives the maintenance schedule for the analyzer. The maintenance schedule shows the time intervals for maintenance tasks. Maintenance tasks may need to be done more frequently depending on the operating environment.
Table 17 Maintenance tasks and schedule
Daily
X
Monthly Quarterly Annually Maintenance task
Look for alarms or events. An indicator light is illuminated or flashes when an alarm or event has occurred. Refer to
Look for liquid leaks and other conditions that are not typical. Repair leaks immediately to prevent analyzer damage.
Look at the flow meter reading for the UV reactor carrier gas flow. Make sure that the reading is stable and approximately the same reading that was recorded during initial start-up.
Examine the GLS and sparger. Make sure that the sparge gas bubbles flow correctly.
Note: The sparger on the TC version is bypassed with the conversion.
Prepare the reagents and fill the 5-gallon containers. (Some reagents last two months).
Calibrate the analyzer with fresh span standards.
Make sure that the pressure of the carrier gas is
sufficient. Refer to Attach a carrier gas
on page 23.
Examine the analyzer to see if it is dirty. Clean the exterior of the analyzer if necessary.
X
X
X
X
X
X
X
50 English
Table 17 Maintenance tasks and schedule (continued)
Maintenance task
Install new peristaltic pump tubing. Refer to
Replace the pump head and pump tubing
on page 53.
Examine the UV lamps and make sure that the lamp surfaces are clear. If the lamp surfaces are
not clear, start a cleaning cycle. Refer to Manual control
on page 48. Before the analyzer is put back online, wrap standard aluminum foil around each lamp to prevent UV exposure.
Clean the IR sample cell and windows with an
applicable solvent. Refer to Clean the IR cell
on page 56.
Daily Monthly Quarterly
X
Annually
X
X
Clean the analyzer
D A N G E R
Electrocution hazard. Remove all power from the instrument and relay connections before this maintenance task is started.
N O T I C E
Potential Instrument Damage. Delicate internal electronic components can be damaged by static electricity, resulting in degraded performance or eventual failure.
Clean the external surfaces of the analyzer and the internal surfaces of the lower cabinet with a damp cloth and a mild detergent.
After the analyzer has been in operation for approximately one month, examine the IR cell. Make sure that the cleaning process and solution are sufficient to keep the internal system clean. Adjust
the auto cleaning schedule as necessary. Refer to Schedule validations, calibrations and cleaning
on page 33. Clean the internal system at least once a year.
Cleaning solutions
D A N G E R
Chemical exposure hazard. Gas from a chlorine compound and UV light reaction can cause death. Do not use chlorine compounds for cleaning.
D A N G E R
Chemical exposure hazard. UV light reacts with some solutions to form a dangerous gas. If a dangerous gas can form with the solution that is used, keep the UV lamps off.
Use a cleaning solution to clean biological films or compounds that can collect or crystallize in the
plumbing. Use a cleaning solution as specified in Table 19 .
The cleaning solution must not dissolve or damage the instrument components or produce harmful gases or by-products. The applicable instrument components are shown in
.
If the clean cycle is not effective, adjust one or more of these options:
• Cleaning interval
• Cleaning duration
• UV lamp mode if safety is not compromised—refer to Table 19
• Cleaning solution
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Component
Fittings
Manifolds
O-rings
Valve seals
IR cell
Tubing
Glassware
Table 18 Internal components
Composition
Polypropylene
Acrylic
Silicone
Viton, Kalrez
PVDF
PFA/stainless steel, Norprene A-60-G, Tygon R-3603
Quartz, borosilicate glass
Table 19 Cleaning solutions and UV lamp mode
Cleaning solution
DI water
50/50 mix (by volume) of H
3
PO
4
and Na
2
O
8
S
2
1.0 M sodium hydroxide
10% HCl
5% acetone
UV lamp mode
ON or OFF
ON or OFF
OFF
OFF
OFF
Shutdown procedure
D A N G E R
Electrocution hazard. Remove power from the instrument before doing maintenance or service activities.
W A R N I N G
Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled. Refer to the current material safety data sheets (MSDS) for safety protocols.
C A U T I O N
Health hazard. Hazardous levels of ozone can be generated if the UV lamps are left on while only air moves through them.
N O T I C E
Failure to do the correct shutdown procedure can cause damage to the instrument when the instrument is started again.
• The analyzer is designed for continuous operation. The useful life span of the UV lamps is decreased if the lamps are turned on and off when not necessary.
• Do not allow the UV lamps to stay on when liquid is not flowing through the reactor. Blockage and/or damage may occur.
• If measurement is not necessary or possible, use deionized water for sample in the analyzer.
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To shut down the analyzer:
1. Replace all reagent containers with distilled or deionized water.
2. Turn off the UV lamp(s) from the Service/Relay test/lamps screen.
3. Flush the analyzer with the distilled or deionized water for 10 minutes.
4. Stop the analyzer to turn off the pumps. From the main menu, push the DOWN arrow, then push
ENTER.
5. Disconnect the gas line between the GLS and the IR manifold.
6. Flow clean, dry nitrogen or purified air through the IR cell to dry and clean it.
7. Turn off the main power to the analyzer.
Replace the pump head and pump tubing
D A N G E R
Electrocution hazard. Remove all power from the instrument and relay connections before this maintenance task is started.
C A U T I O N
Pinch hazard. Remove power from the instrument before maintenance or service activities are done.
Required items:
• Tube loading key
• Flat blade screwdriver
Flush the analyzer with DI water for 20 minutes before this procedure.
Refer to Replacement pump kits
on page 80 for replacement tubing and barb information. Refer to
on page 83 for replacement pump information. Use barb reducers to connect any reduction tubing as given in the pump kit instructions. For best operation, use only the minimum lengths of tubing necessary.
Loosen the four captive screws and swing out the pump module to make the pump accessible. Refer
.
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Figure 16 Pump module assembly
1 Pump module assembly
2 Captive screws
3 Pump module prop (2x)
4 Acid pump head
7 Tubing route for standard pumps
8 Tubing route for optional pumps
9 Persulfate pump head
10 Optional Sparger waste pump head (Turbo analyzers only)
11 Resample pump head 5 Sample pump head
6 Optional dilution pump (Process analyzers only)
pump tubing has been installed.
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Figure 17 Replace pump tubing
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Clean the IR cell
D A N G E R
Electrocution hazard. Remove all power from the instrument and relay connections before this maintenance task is started.
Clean the IR cell at least once a year or when results become irregular. Refer to the illustrations in this section for IR cell removal.
1. Remove the inlet and outlet tubing from the IR cell. Refer to
on page 59.
2. Support the mirror assembly to prevent the cell assembly from falling out if the thumb latch releases unexpectedly. Refer to
on page 59.
3. Cut the tie wrap. Refer to Figure 19
on page 59.
4. Pull the thumb latch away from the cell assembly to release it. Refer to Figure 19 on page 59.
5. Clean the interior wall of the cell assembly with lint-free tissues and isopropyl alcohol. Refer to
.
6. Use cotton swabs and isopropyl alcohol to clean the sapphire window that protects the parabolic mirror. Refer to
.
7. Do an inspection of the assembly to make certain that all debris and contamination are fully removed and that the sapphire is not scratched or cracked.
8. Make sure that the parabolic mirror is not discolored. If the mirror is discolored or the sapphire is damaged, replace the cell assembly.
9. Clean the sapphire window in the IR bench with the same procedure used to clean the cell
assembly window. Refer to Figure 18
.
10. Remove the O-ring between the cell and the bench assembly.
11. Do an inspection of the O-ring and look for damage, debris or deterioration. Install a new O-ring if the O-ring shows damage, debris or deterioration.
12. Do an inspection of the inlet and outlet ports for obstructions or contamination. Remove obstructions or contamination with cotton swabs and isopropyl alcohol.
13. Install the tubing and a new tie wrap.
14. Do a pressure/leak test. Refer to
Pressure/leak test on page 57.
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Figure 18 Clean the IR cell
1 Sapphire window
2 IR mirror assembly
3 O-ring (between IR bench and mirror assemblies)
4 IR bench assembly
Pressure/leak test
D A N G E R
Electrocution hazard. Remove all power from the instrument and relay connections before this maintenance task is started.
C A U T I O N
If relay contacts are connected to AC line voltage, remove the main power to the analyzer before the top enclosure door is opened.
Do a pressure/leak test to make sure that the O-rings are correctly installed and have sealed the IR cell assembly.
1. Remove the outlet tube from the IR cell assembly and plug the outlet tube.
2. Monitor the bubbles in the GLS U-tube. If the bubbles travel consistently from front to back, the cell O-rings give a sufficient seal.
Note: Failure of this test may also indicate a cracked condenser or leaky GLS fitting.
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Replace the IR cell
D A N G E R
Electrocution hazard. Remove all power from the instrument and relay connections before this maintenance task is started.
Note: After a new IR cell is installed, the thumb latch must be adjusted. Improper adjustment of the thumb latch can damage a new IR cell assembly and make it impossible to correctly align the mirror.
1. Remove the inlet and outlet tubing from the IR cell. Refer to
.
2. Disconnect the power connector from the I/O board.
3. Support the mirror assembly to prevent the cell assembly from falling out if the thumb latch releases unexpectedly. Refer to
.
4. Cut the tie wrap. Refer to Figure 19
.
5. Pull the thumb latch away from the cell assembly to release it. Refer to Figure 19 .
6. Install the new IR mirror assembly and connect the power connector to the I/O board.
7. Install a new tie wrap.
8. Restore power and do a pressure/leak test. Refer to
Pressure/leak test on page 57.
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Figure 19 Remove the IR cell
1 IR bench assembly
2 Indentation for latch piston
3 Latch piston
4 Inspector lacquer
5 Power connector
6 Latch handle
7 Tie wrap
8 Inlet fitting and tubing
9 IR mirror assembly
10 Outlet fitting and tubing
Calibrate IR gas
D A N G E R
Electrocution hazard. If relay contacts are connected to AC line voltage, remotely disconnect the power before opening the upper enclosure door of the analyzer.
N O T I C E
Potential Instrument Damage. Delicate internal electronic components can be damaged by static electricity, resulting in degraded performance or eventual failure.
CO
2
span gas at 1000 ppm or 10000 ppm is necessary to do this procedure. For IR span, ppm CO
gas range, refer to Hardware configuration
on page 83.
2
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Zero gas can be the carrier gas. Connect the zero and span gases directly to the IR manifold.
Calibrate the IR gas when the IR is out of calibration. Make sure that the feed pressure at the carrier gas inlet is 40-90 psig.
1. In the Service/Elevation menu, set the elevation to 1 m.
2. In the Service menu, push the up arrow three times.
The display shows the IR cal screen.
3. Make sure that the temperature of the IR cell is in the range of 48 to 51 °C. Apply the zero gas directly to the cell. Let the gas flow for 10 minutes at 200 cc/minute.
4. Identify the IR span gas concentration (1000 ppm or 10000 ppm CO
2
). Refer to Hardware configuration
on page 83. If the span gas is 1000 ppm, LK1 must be out. If the span gas is
10000 ppm CO
2
, LK1 must be in. Refer to Figure 20
on page 61.
Zero adjustment
Make the zero adjustment on the 8000 display/controller board. Refer to
1. Turn the screw clockwise to increase the voltage. Turn the screw counterclockwise to decrease
the voltage. Refer to Figure 20 .
2. When the zero gas reading is stable, adjust the Zero potentiometer so that the voltage is between
0.26 and 0.27 V.
0.27 V gives a CO
2
ppm reading slightly above zero. 0.25 V gives a zero reading, but the actual gas ppm reading on the display could be zero or below zero. The slight increment above zero makes sure that the gas ppm reading is in a positive range.
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Figure 20 Adjust the zero potentiometer on the 8000 controller PCB
1 Contrast adjustment
2 LK1-IR range selection (OUT=0-1000 ppm,
IN=0-10000 ppm)
3 Span adjustment
4 TP4-IR voltage 0.25V-4.75 V (at sea level only)
5 Zero adjustment
6 TP3 Analog ground (Ø V)
7 TP1-INT output
8 TP5-SIG IN (input signal from IR bench)
9 LK2-IN-AGC setup
10 LK5-LK8-IN
11 TP2-Source voltage 1.7 V
12 Source voltage adjustment to 1.7 V
13 LK4-OUT (stepper inputs)
14 TP6-Digital 0 V
15 LK3-EPROM
Span adjustment
1. Connect the appropriate span gas (1000 ppm or 10000 ppm) to the IR manifold and let it flow for
10 minutes at 200 cc/minute until the reading is stable.
2. When the reading is stable, adjust the span potentiometer to read the approximate CO
2
(1000 or 10000 ppm).
ppm
3. After the span adjustment is completed, examine the zero adjustment again. The span and zero adjustments interact. Adjust the zero setting and the span setting back and forth as necessary to get correct last adjustments.
Note: Noise can cause minor fluctuations in the readings. If the fluctuations bracket the wanted values, the readings are acceptable.
4. If the span gas does not yield 1000 ppm ±5 ppm or 10000 ppm ±50 ppm, make sure that the
LK1 jumper position is correct. Refer to
Hardware configuration on page 83. If necessary,
contact the manufacturer.
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Clean the gas liquid separator (GLS)
D A N G E R
Electrocution hazard. Turn off all pumps and lamps before servicing the GLS. Disconnect power to the relays before opening the analyzer top enclosure door.
C A U T I O N
Personal injury hazard. If the analyzer has not been flushed with deionized water for 20 minutes, some acid and persulfate is still in the inlet tubes and the peristaltic tubes. Use caution when removing the tubes as the acid and persulfate may spray out.
1. Turn off main power to the analyzer.
2. Disconnect the four finger-tight connectors and slide the GLS down to remove the GLS from the
).
3. Invert the GLS to remove accumulated sediment. Flush with deionized water from a squeeze bottle if necessary. Remove algae accumulations with a cotton swab and deionized water.
Figure 21 Clean the gas liquid separator (GLS)
Fuse replacement
D A N G E R
Electrocution hazard. Remove all power from the instrument and relay connections before this maintenance task is started.
N O T I C E
Potential Instrument Damage. Delicate internal electronic components can be damaged by static electricity, resulting in degraded performance or eventual failure.
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D A N G E R
Fire hazard. Use the same type and current rating to replace fuses.
Figure 22 shows the locations and specifications of the fuses.
Figure 22 Fuse locations and descriptions
1 F2-External valve fuse
2 F3-Con25 and fan fuse: 1 A anti-surge 250 V
(IEC127 Sheet III Type 2)
3 F1-UV lamp fuse
4 F4-RS422/485 fuse: 4 A anti-surge 250 V
(IEC127 Sheet III Type 2)
5 Printed circuit board
6 F5 fuse holder
7 Power supply terminal fuse: 2 A anti-surge 250 V
(IEC127 Sheet III Type 2)
8 Power supply cover
9 Cover screws (4x)
Troubleshooting
D A N G E R
Multiple hazards. Only qualified personnel must conduct the tasks described in this section of the document.
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Preliminary checks
1. Make sure that the proper electrical power is supplied to the analyzer.
2. Make sure that the fuses are good.
3. Make sure that the liquid and gas supplies are present and sufficient.
4. Make sure that all drains, sample and gas lines have no kinks, restrictions or leaks. If necessary, refer to the user instructions for TC conversion and flow diagram.
Instrument does not calibrate
Do liquid tests that require changes to the plumbing after a purge cycle so that there is no contact with samples and reagents.
1. Make sure that the sample flow is sufficient. Put a finger over the IR cell outlet (vent) and look at the GLS U-tube. Make sure that bubbles move in the U-tube from front to back.
2. Make sure that the overflow portion of the GLS is filled with water and drains correctly.
3. Look at the water level in the back-pressure gauge on the GLS and make sure that it is at the operation level.
4. If there is an increase in pressure (caused by a clog or obstruction), the U-tube liquid seal is pushed down on the right side and gas bubbles appear around the bottom of the U-tube. Remove the clog or obstruction.
5. If bubbles are forced through the drain, there is too much back pressure in the IR or vent line.
Clean or replace the IR tubing.
6. Stop the analyzer, refer to Shutdown procedure on page 52.
7. Disconnect the carrier gas supply to the UV manifold. Fold the carrier supply tubing to obstruct flow or use a fitting to prevent flow. The flow meter shows the carrier flow is zero and an alarm might be generated as the reactor has been pressurized.
8. Put a plug into the sparger block manifold outlet that is connected to the resample pump.
9. Put the inlet to the resample pump in a new calibration standard.
Note: In dilution analyzers, it might be necessary to dilute the standard by the dilution fact, normally 10. If needed, use the tubing from the start-up kit for this procedure.
10. Reconnect reagents and start the analyzer.
Note: Step 11 should not be done with acid and persulfate in the analyzer.
11. Use water instead of acid and persulfate to make sure that the delivery rates (mL/min) of all pumps match the hardware configuration table. Use a small measuring cylinder to measure how much water is taken from the cylinders.
Instrument readings are not stable or drift
1. Make sure that electrical input wiring is correctly installed.
2. Make sure that the nitrogen flow rate is stable.
3. Make sure the carrier gas feed pressure is correct. If needed, calibrate the IR gas. Refer to
4. Look for pinched or incorrectly installed pump tubing.
Periodic spikes in the readout
Large particles in the sample cause periodic spikes in the readout. At elevated temperatures, persulfate bubbles can also cause dips followed by spikes in the output.
1. Look for large particles in the sample. Mix the sample sufficiently.
2. Make sure that the large particles do not go into the reactor.
3. Do not go beyond the molarity specified in Table 9 on page 26.
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Identify a carrier gas leak
Do this procedure to identify and fix a carrier gas leak.
1. Make sure that the fittings, barb connections etc for the carrier gas lines are tight. Tighten any loose connections.
2. Make sure that there is an air/gas interface in the UV reactor manifold. Refer to Figure 2
on page 9.
The air/gas interface frequently moves up and down where the carrier gas contacts the persulfate and resample solution which flows up.
3. In the top enclosure, pinch closed the right tygon tube. Refer to Figure 19
on page 59.
4. Make sure that the bubbles in the GLS U-tube consistently move from front to back. If not, a leak is present or the condenser has a crack. Refer to
5. In the top enclosure, pinch closed the left tygon tube that contains flow from the IR detector.
Refer to
6. Make sure that the bubbles consistently move from the front to back of the GLS. If not, a leak is present at the flow cell on the IR bench.
Maintenance codes
Code Description
M01 (Zero stability) Four attempts at a zero calibration have been made and failed.
Diagnosis
During the cleaning delay, insufficient carbon is removed.
This results in a significant oxidation during a baseline, and causes the CO
2 to vary.
Corrective action
Make sure that:
• The clean period is sufficient and the cleaning solution is sufficient for the application.
• The pre zero period is set to a value greater than the response time of the analyzer.
The carrier flow rate is varying.
The purity of the DI water varies or there is not enough water.
Make sure that the flow meter gas supply is at a constant pressure.
Make sure that:
• The purity of the zero standard is sufficient and replace if necessary.
• The peristaltic pumps operate correctly.
• The calibration valves are fully open.
The persulfate has carbon impurities.
Fluid or gas system leaks.
Poor IR cell heater control.
Faulty IR
Use carbon free persulfate only.
Fix all leaks.
Make sure that the cell temperature is constant 49 °C ±1 °C.
Contact technical support.
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Code
M02 (Zero standard level)
Description
The zero standard produces a CO
2
level that is too high.
M03 (Span stability) Four attempts at a span calibration have been made and failed.
Diagnosis
High CO
2
level
The purity of the DI water varies or there is not enough water.
Corrective action
Calibrate the IR again. Use carrier gas in the IR input and make sure that IR reads zero.
Make sure that:
• The purity of zero standard and replace if necessary.
• The peristaltic pumps operate correctly.
• The calibration valves are fully open.
The persulfate has carbon impurities.
Fluid or gas system leaks.
The carrier gas has a high CO
2
content.
The purity of the standard solution is bad, there is not enough solution, or solution has not been introduced for long time.
Use carbon free persulfate only.
Fix all leaks.
Increase purity of carrier gas.
• Make sure that there is a constant flow of standard.
• Make sure that the calibration valves are fully open.
• Increase the Pre span delay to make sure that the analyzer has a stable IR CO
2
reading before a span is performed.
The persulfate has carbon impurities or it is not delivered constantly.
The TIC extraction/acid mix is not constant. This can be because of no TIC extraction or an irregular supply of acid. If there is no
TIC in the standard, the acid is a small diluent to the sample that gets into the reactor.
Make sure that the persulfate delivery system is in good condition.
Make sure that the acid delivery system is constant and that there are no impurities in the acid. Use fresh TIC free calibration standard.
Leaking fluid or gas system
Poor IR cell heater control
Fix all leaks.
• Make sure that the cell temperature is constant 49 °C
±1 °C.
• Increase span size.
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Code
M04 (Span standard level)
M05 (Maintenance
%)
M06 (Validation %)
Description
In order to pass an auto calibration, it is necessary to get 65% of the theoretical
CO
2
for the applied standard.
For example, if the analyzer is calibrated with 10000 ppm
CO
2
and the analyzer is a
1000 mg/L analyzer, and if the single point standard is
1000 mg/L, it is expected that the gas produced will be at least 6500 ppm CO
2
.
Expected CO
FSD
2
= 0.65 x FSD gas x CAL STD ÷ Analyzer
Expected CO
2
= 0.65 x
10000 x 1000 ÷ 1000
= 6500 ppm CO
2
The difference between the current calibration and the primary calibration is more than the Maint % Primary setting. Refer to
Change the tolerance settings (not recommended)
on page 42.
The validation result (%) is different by more than the validation tolerance setting.
Refer to Select validation, calibration and cleaning options on page 34.
Diagnosis
Oxidation is not sufficient, caused by insufficient persulfate (supply or strength) or weak or bad UV lamps.
Bad standard.
Fluid leak.
—
—
Corrective action
• Make sure that the condition of the persulfate delivery system is good.
• Make sure that the concentration of persulfate is correct.
• Look for a broken lamp.
Mix a new standard and make sure that it matches the value entered in the Single cal std menu.
Fix all leaks.
• Increase the Maintenance % in the Setup\Tolerance
\Maintenance % Screen.
• Replace peristaltic pump tubing and perform a primary and calibration.
• Make sure that the standard is the correct mg/L.
• Calibrate the analyzer again.
• Increase the validation %.
• Make sure that the standard concentration that is selected is correct.
M07 (Calibration failure)
M08 (Reactor flow)
The difference between the current calibration and the primary calibration is more than the Fault % Primary setting. Refer to
Change the tolerance settings (not recommended)
on page 42.
—
The UV reactor pressure is greater than the Maint
Pressure setting. Refer to
on page 42.
The UV reactor flow is restricted.
• Replace peristaltic pump tubing and perform a primary calibration.
• Edit the entry in the
Setup/Tolerance/Fault % Pri
Screen.
• UV manifold crystal buildup in the UV block. Clean the UV manifold.
• Blocked UV reactor.
Disassemble the reactor and flush with water to remove this blockage.
M09 (Low reagents) One of the level detectors for the reagents has detected a low reagent level.
To disable this feature, refer
on page 70.
—
• Refill the bottles.
• Make sure that the jumper settings are correct.
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Code
M10 (Low cell temperature)
Description
The temperature of the flow cell in the IR detector is too low.
M11 (Spill detection) The TOC level is greater than the spill threshold. A cleaning cycle is done for the spill recovery time. Refer to
Select validation, calibration and cleaning options
on page 34.
To disable this feature, increase the spill threshold setting.
M12-M16 (Not allocated)
—
Diagnosis
Cell heater plug not connected to
8001 I/O PCB assembly.
Cell heater faulty.
Indicator light repeatedly turns on and off.
Erratic cell temperature
Corrective action
Connect IR cell heater. Determine if
IR cell is warm to touch.
Replace the cell heater.
Stop the analyzer. If the cell temperature becomes stable:
• Replace any failed UV lamps.
• Replace the UV power supply.
— —
— —
Fault codes
Code and fault message
F01 (No sparger flow)
Diagnosis
Loss of sample
Note: To disable this feature, refer to
F02 (No UV lamp flow)
F03 (No carrier gas)
False trigger
Loss of persulfate
Loss of resample
The pressure switch has detected low carrier pressure.
Corrective action
• Disable the flow sensing in the
Service\Input status screens. In later firmware versions, the flow failure thresholds must be set to zero.
• Make sure that there are no leaks in the acid line from the tubing or fittings.
• Make sure that sample flows to the analyzer.
Disable the flow sensing in the
Service\Input status screens. In later firmware versions, this might require the setting for flow failure thresholds be set to zero.
Make sure that there is persulfate supply.
Make sure that there are no leaks in resample.
• Make sure that there is carrier gas.
• Replace the pressure switch.
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Code and fault message
F04 (Drain level)
F05 (Not allocated)
F06 (Reactor flow)
F07-F08 (Not allocated)
F09 (IR detector)
Diagnosis
The analyzer has detected that the level sensor in the drain pan has been actuated.
The analyzer has a leak and the drain has a blockage.
The level sensor is installed with the wrong orientation.
—
The pressure in the UV reactor is greater than the specified value in the Fault Pressure Threshold in
Setup/Tolerances. The reactor flow is restricted.
Corrective action
—
Make sure that the drain is clear.
Invert level sensor.
—
• UV manifold crystal buildup in the
UV block. Clean the UV manifold.
• Blocked UV reactor.
Disassemble the reactor and flush with water to remove this blockage.
—
The Automatic Gain Control level on the IR has reached an unacceptable level.
—
—
Examine and clean the optics in the
IR cell. Refer to Clean the IR cell
on page 56.
— F10-F16 (Not allocated)
Service menu
Use the Service menu to find if there is a hardware problem. The analyzer shows an offline status when a service menu other than input status screen is used.
1. Push Ctrl + Down arrow to access the Service menu from the main operating screens. The screen shows "Service."
2. Push ENTER. The relay test menu is shown.
Test the relays
N O T I C E
Possible instrument damage. If the carrier loss input is disabled, the pumps run when the carrier is not present.
This can result in damage to the carrier gas system due to liquids that flow back through the carrier gas components.
Use the Relay test menu to toggle the status of the S1-S5 relays, the blowback valve, lamps and pumps. The screen shows "Relay test."
Note: If a relay is activated, an alarm system connected to the relay might be activated.
1. Push ENTER.
2. When prompted, type the pass code (1953) and push ENTER again. The S1 relay status screen shows "S1 relay ON."
3. Push ENTER to toggle the relays between ON and OFF. Push the up arrow to access the
S2 relay and enter the status of the S1 relay (ON or OFF) into memory. The S2 relay status screen is displayed. The Blowback screen, the Lamp screen and the Pumps screen show "ON."
4. Use the up and down arrows to move through the screens.
Note: In these screens, HI/LO only allows a change to be seen for the logical level of the input. It does not refer to the High or Low nature of the parameter that is monitored.
5. To enable or disable a function, push ENTER. Asterisks flash on either side of Enable or Disable.
Push the up and down arrows to toggle between Enable and Disable. Push ENTER to save and store your selection.
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6. Push the up and down arrows to continue to the next screen.
7. To exit the input status function, push Ctrl and then ENTER.
Test the valves
D A N G E R
Explosion hazard. Do not connect or disconnect electrical components or circuits to the equipment unless power has been removed or the area is known to be non-hazardous.
These menus turn on the streams, clean and calibration valves. The standard analyzer does not have a connection to V4 terminals.
1. Push the up arrow in the Relay test menu to access the Valve test menu. The screen shows
"Valve Test."
2. Push ENTER.
3. When prompted, type the pass code (1953) and push ENTER again. The Online valve V1 status screen is displayed.
4. Push ENTER to toggle between ON/OFF status. This displayed selection is saved when the screen is exited.
Each time the up arrow is pushed, the Clean valve V2, STD valve V3 and Valve V4 screens are shown in succession. Push ENTER to toggle between ON/OFF status.
Note: In normal operation, the stream valve V4 is temporarily disabled when V1 is switched on.
Change the input status
N O T I C E
Possible instrument damage. If the carrier loss input is disabled, the pumps run when the carrier is not present.
This can result in damage to the carrier gas system due to liquids that flow back through the carrier gas components.
The Input Status menus allow the level of the logical input to be measured and allow the action of the input to be enabled. The actual logical input levels (HI and LO) are not significant as long as they change when the actuator state is changed. If an input is disabled, it will not cause an event warning or fault to occur.
1. Push the up arrow from the Valve test menus to access the Input status menus. The screen shows "Input status."
2. Push the up or down arrow. When prompted, type the pass code then push ENTER again.
3. Push the up or down arrow to move through the screens.
Note: In these screens, HI/LO only allows a change to be seen for the logical level of the input. It does not refer to the High or Low nature of the parameter that is monitored.
4. Push ENTER to enable/disable a function. Asterisks will flash on either side of Enable or Disable.
5. Push the up or down arrow to select Enable or Disable.
6. Push ENTER to save and store the selection.
7. Push the up or down arrow to go to the next screen.
8. Push Ctrl + ENTER to exit the Input status function and return to the Input status menu.
Calibrate the analog outputs
Before the analog outputs are calibrated, connect two analog circuits to the circuit loop which operates the analyzer for at least 5 minutes. The circuit loop must not be broken (open-circuited) during the adjustment of zero and span while the DCS loop load resistor is in position.
Note: The analog outputs can be calibrated to be the same as the input of a DCS system to get accurate repeating of signalled values.
1. Push Ctrl .
70 English
The Service screen is shown.
2. Push ENTER.
The first option in the Service screen is shown, "Relay Test".
3. Push until "Output Adjust" is shown, then push ENTER.
"CH1" (analog output 1) is shown.
4. Push ENTER.
The first option in the CH1 screen is shown, "CH1 Zero".
5. Use the arrow keys select an option.
Option Description
CH1 Zero
Sets the digital count for the zero value (4 mA output)—0 to 1024 counts.
Make sure that on the multimeter 4 mA is measured at CH1 or that 0 is shown continuously on a
DCS.
CH1 Span Sets the digital count for the span value (20 mA output)—1025 to 4095 counts.
Make sure that on the multimeter 20 mA is measured at CH1 or the appropriate TOC value is shown continuously on the DCS.
CH1 Test
Lets the user make sure that the analog output is linear over the 4-20 mA range. Use the arrow keys to scroll.
Make sure that on the multimeter:
• 4 mA is measured when 0% is shown
• 12 mA is measured when 50% is shown
• 20 mA is measured when 100% is shown
6. Push ENTER to change the value on the screen.
Asterisks flash on both sides of the value.
7. Use the arrow keys to change the value, then push ENTER to save.
8. Push Ctrl ENTER.
"CH1" is shown.
9. Push until "CH2" is shown, then push ENTER.
10. Do steps
–
7 to calibrate the other analog output (CH2).
Set the elevation
The IR can be calibrated at different elevations and atmospheric pressures. The elevation is normally set to 1 m for locations that are at or close to sea level. If the analyzer is operated at substantial elevations with the factory calibrated IR, set the menu to the local elevation. If the analyzer is gas calibrated on site with the instructions in this manual, it is not necessary to enter the local elevation.
Set the elevation to 1 m.
Adjust the UV block
To get the correct default bubble threshold constants for each analyzer range, use the Service/UV
Block menu. This menu lets the block to be selected by part number. All of the original acrylic blocks can be treated as the part number 011664. The default selection in this release of firmware is the old block (011664).
To be effective, the UV Block menu must be selected after the analyzer is selected. The default values can be overridden with the Sparger Flow and UV Flow menus.
Replacement parts and accessories
Note: Product and Article numbers may vary for some selling regions. Contact the appropriate distributor or refer to the company website for contact information.
English 71
Table 20 Replacement parts
Description
Block, Angled Input, Sample/DI, TOC Analyzers
Block, Orifice, TOC Analyzers
Cable, Ribbon, 8000/8001
Cable, Ribbon, IR, TOC analyzer
Cell Assembly, Kynar, Integral Mirror
Condenser Assembly UV (Process UV only)
Condenser Assembly (Turbo UV only)
Condenser Pre-Cooler (SS Coil) (Turbo UV only)
Fan, 2.36-in., 24 V
Flow Controller, Silver/ Green
Flow Element, 465, Black/ Silver
Flow Meter, 0–200 cc, 65 mm
Flow Meter, 300 cc, 65 mm, w/o Valve
GLS, TOC Analyzer (Process UV only)
GLS, TOC Analyzer Bypass Drain (Turbo UV only)
Hardware, Pump Mounting 3-head SS
Hardware, Pump Mounting 2-head SS
Lamp Assembly, UV, TOC Analyzers
Manifold, Top, Sparger, TOC Analyzers
Manifold, Valve, TOC Analyzers
Manifold, Bottom, Sparger, TOC Analyzers
Manifold, UV TOC Analyzers
Mixer Assembly TOC UV
Motor, Pump, 2 RPM, TOC Analyzers (Process UV only)
Motor, Pump, 6 RPM, TOC Analyzers
PCB, Display, 8000, Assembly
PCB, Flow, Assembly
PCB, Termination, 8001, Assembly
PSU Assembly, TOC Analyzers
PSU, UV, 30 mA, Absopulse (For replacement of older obsolete models, refer to the kit tables below.)
Power Supply, 150 W, Switchable 1
Regulator, Pressure, 0–30 PSI
Surge Suppressor, 240 V ac
Switch, Pressure, 15–60 PSI
Tubing PFA,
1
/
8
-in. OD x 0.062-in. ID (per ft)
72 English
Item no.
010333
110131
011581
011582
011583
011664
120228
024102-01
024102-02
130135
130137
130143
110142
020011
014726
021045
020589
021127
020585
020590
010178
011604
011588
110152
110153
120191-01
120210
120239
020592
5885700
025020
014699
58444-00
016183
026009
Table 20 Replacement parts (continued)
Description
Tubing Tygon 7016 (per ft, 50 ft min.)
Tubing Tygon 7017 (per ft, 50 ft min.)
Tubing Tygon
3
/
8
-in. ID x 1/2-in. OD (per ft)
Tubing Kit, acid and persulfate tubing, 6 each (Turbo UV only)
Tubing Norprene 7013 (per ft, 50 ft min.)
Tubing Norprene 7014 (per ft, 50 ft min.)
Tubing Norprene 7015 (per ft, 50 ft min.)
Tubing Norprene 7016 (per ft, 50 ft min.)
Tubing, PFTE,
1
/
8
-in. OD x 0.030" ID (per ft)
Tubing Norprene 7024 (per ft, 50 ft min.)
Valve, 3-way, Burkert, 125 MAN
Valve, 3-way, Burkert, 125 MAN, Class 1, Div 2 UL for Dual Stream Operation
Valve, 3-way, Burkert, 127 MAN
Valve, 3-way, Burkert FM (for Blowback Filter)
Valve, Manifold Assembly (Complete with valves)
Weight, Reagent, PVC,
1
/
8
-in. NPT
Weight, Reagent, SST,
1
/
8
-in. NPT
Table 21 Reagents and calibration standards
Description
Phosphoric Acid Solution, 0.1 Molar
Phosphoric Acid Solution, 0.3 Molar
Phosphoric Acid Solution, 0.6 Molar
Phosphoric Acid Solution, 1.0 Molar
Sodium Persulfate Kit, 4-Jar Case (sold in North America only)
Sodium Persulfate Solution, 0.2 Molar
Sodium Persulfate Solution, 0.4 Molar
Sodium Persulfate Solution, 0.6 Molar
Sodium Persulfate Solution, 0.8 Molar
Sodium Persulfate Solution, 1.0 Molar
Sodium Persulfate Solution, 1.2 Molar
Sodium Persulfate Solution, 1.5 Molar
TOC Standard, 2.0 mg/L
TOC Standard, 5.0 mg/L
TOC Standard, 10.0 mg/L
TOC Standard, 25.0 mg/L
Qty
20 Liter
20 Liter
20 Liter
20 Liter
4 Liter
4 Liter
4 Liter
4 Liter
20 Liter
20 Liter
20 Liter
20 Liter
1
20 Liter
20 Liter
20 Liter
Item no.
58454-00
58455-00
58456-00
58457-00
58462-00
58471-00
58467-00
58463-00
58458-00
58459-00
58460-00
58461-00
040005
58451-00
58452-00
58453-00
English 73
Item no.
026067
026071
014458
6023700
014459
024105
120214
011622
54838-00
026014
026015
026017
200143
026043
026044
026045
026046
Table 21 Reagents and calibration standards (continued)
Description
TOC Standard, 50.0 mg/L
TOC Standard, 100.0 mg/L
TOC Standard, 200.0 mg/L
TOC Standard, 500 mg/L
TOC Standard, 1000 mg/L
TOC Standard, 2000 mg/L
TOC Standard, 5000 mg/L
TOC Standard, 10000 mg/L
TOC Standard, 20000 mg/L
ZERO Solution, <0.05 mg/L TOC
TOC Standard, 5 mg/L, Benzoquinone
ZERO Solution, <0.05 mg/L TOC
Qty
4 Liter
4 Liter
4 Liter
4 Liter
4 Liter
4 Liter
4 Liter
4 Liter
4 Liter
4 Liter
1 Liter
4 Liter
Item no.
58472-00
58468-00
58464-00
58473-00
58469-00
58465-00
58474-00
58470-00
58466-00
58477-00
58476-00
58477-00
Table 22 Pump kits
Description
Kit, 7013 Pump (Process UV only)
Kit, 7014 Pump (Process UV only)
Kit, 7015 Pump (Process UV only)
Kit, 7016 Pump (Process UV only)
Kit, 7024 Pump (Process UV only)
Kit, 7014 Pump, T/T LH (Turbo UV only)
Kit, 7024 Pump, Barb Reduced (Turbo UV only)
Kit, 7014 Pump, T/T RH (Turbo UV only)
Kit, 7015 Pump, Barb Reduced (Turbo UV only)
Kit, 7016 Pump, Barb Reduced (Turbo UV only)
Kit, 7016 Pump (Turbo UV only)
Table 23 Start-up kits
Description
Start-up Kit, TOC UV analyzers (Process UV only), includes:
Start-up Kit, TOC UV Turbo analyzers (Turbo UV only), includes:
Barb adapter ¼–28 x 0.08 (Turbo UV only)
Barb adapter ¼–28 x 0.102 (13)
Barb adapter ¼–28 x 0.129 (14)
Barb adapter ¼–28 x 0.164 (16)
Qty
2
2
1
1
2
2
Item no.
200122
200148
013830H
013829
013828
013827
Item no.
200117
200118
200119
200120
200138
200139
200140
200141
200142
54147-00
200120
74 English
Table 23 Start-up kits (continued)
Description
Hex Ballend Driver, 2.5 mm
Hex Ballend Driver,
3
/
32
Hex Ballend Driver, 16, 3 mm
Hex Ballend Drive, 4 mm
Nut Driver,
5
/
16
AF
Bottle kit 2 x 5 gal, 2 x 4 L, tube weights, reagent bottle tray (Turbo UV only)
Brush, Sparger
Case Assembly, HC6
Ferrule,
1
/
8
SF, ETFE YEL
Filter, hydro., dual Luer L
Fitting, 0.470 Cable, H20
Fitting, ¼ T x
1
/
8
NPT MA
Fitting, ¼ x
1
/
8
T, PP
Fitting,
1
/
8
NPT x
1
/
8
T, BL
Fuse, 1 A, 5 x 20, Antisurge
Fuse, 4 A, 5 x 20, Antisurge
Kit, Bottle
Label, 115 V, 60 HZ
Label. 230 V, 50 HZ
Membrane, Hydrophobic, 0.6
Nut, Fitting,
1
/
8
T, White
Nut, Flangeless,
1
/
8
” (ET)
O-ring; #009 Silicone, 70
O-ring, #013 Silicone, 70
O-ring,#012 Silicone, 70
Plug, 1/4–28
Reagent Storage Tray, Clear (Process UV only)
Rubber Disc
Tailpipe, Drain, SS, 1-
1
/
2
”
Tube-in-tube assembly, acid, TOC analyzers (Turbo UV only)
Tube-in-tube assembly, persulfate (Turbo UV only)
Tubing Norprene 7013 (Process UV only)
Tubing Norprene 7014
Tubing Norprene 7015
Tubing Norprene 7016
Tubing Norprene 7024
Qty
2
4
3
2
2
5
6
2
1
1
1
1
1
1
1
1
5
5
2
2
1
1
4
1
5
5
5
2
2
6
2
2
3
2
2
Item no.
020123
014659
54131-00
019509
013839
120240-02
120240-01
026043
200129
013221
013219
021049
013842
013848
020141
019507
026044
026045
026046
026071
013849
018248
013946
013857
013861
013858
015804
015806
018402
018405
018403
018404
018401
200129
018400
46606-10
English 75
Table 23 Start-up kits (continued)
Description
Tubing PFA,
1
/
8
” OD x 0.062
Tubing, PFTE,
1
/
8
OD x 0.03
Union,
1
/
8
MPT x
1
/
8
T
Table 24 One-year spare parts kit
Description
One-year Spare Parts Kit, TOC UV Analyzers, includes:
Barb Adaptor ¼–28 x 0.08
Barb Adaptor ¼–28 x 0.102 (13)
Barb Adaptor ¼–28 x 0.129 (14)
Barb Adaptor ¼–28 x 0.164 (16)
Barb, Reducer
1
/
8
-in. x ¼-in. (16 x 24)
Barb, Reducer
1
/
8
-in. x
3
/
16
-in. (16 x 15)
Breather, Gelman, 0.2 μm
Fitting, Male Luer to
1
/
8
-in. Barb, PP
Fitting, Male Luer to
1
/
8
-in. NPT thread
Fitting, Tee Female Luer
Elbow,
1
/
8
-in. T x
1
/
8
-in. MP
Ferrule,
1
/
8
-in. SF, ETFE YEL P359X
Fitting,
1
/
8
-in. NPT male plug
Fuse, 1A, 5 x 20, Antisurge
Fuse, 4A, 5 x 20, Antisurge
GLS, TOC Analyzers Bypass drain
Membrane, Hydrophobic, 0.063 x 0.087
Nut, Flangeless,
1
/
8
-in. ETFE P354
O Ring; #009, Silicon, 70 DURO
O-Ring, #013,Silicone, 70 DURO
O-Ring,#012, Silicon, 70 DURO
Plug, ¼–28
Switch, Pressure, 15–60 PSI, Manifold
Tubing PFA,
1
/
8
-in. OD x 0.062-in. ID
Tubing, PFTE,
1
/
8
-in. OD x 0.030-in. ID
Union,
1
/
8
-in. MPT x
1
/
8
-in. T
Valve, 3-way, Burkert, 125 MAN
Valve, 3-way, Burkert, 127 MAN
Qty
4
1
2
2
5
2
1
2
12 feet
12 feet
5
1
1
10
3
1
2
1
5
2
1
5
1
6
5
4
6
1
4
Qty
12
12
5
76 English
Item no.
026009
026067
014016
Item no.
020590
021049
013848
020141
019507
020123
014659
016183
026009
026067
014016
014458
014459
58492-00
58442-00
58441-00
014084
013849
013836
015804
015806
200123
013830H
013829
013828
013827
013831
014038
018248
Table 25 Two-year spare parts kit
Description
Two-year Spare Parts Kit, TOC UV Analyzers, includes:
Barb Adaptor ¼–28 x 0.08
Barb Adaptor ¼–28 x 0.102 (13)
Barb Adaptor ¼–28 x 0.129 (14)
Barb Adaptor ¼–28 x 0.164 (16)
Barb, Reducer
1
/
8
-in. x ¼-in. (16 x 24)
Barb, Reducer
1
/
8
-in. x
3
/
16
-in. (16 x 15)
Breather, Gelman, 0.2 μm
Fitting, Male Luer to
1
/
8
-in. Barb, PP
Fitting, male Luer to
1
/
8
-in. MPT thread
Fitting, Tee, Female Luer
Ferrule,
1
/
8
-in. SF, ETFE YEL P359X
Elbow, Compression
Elbow, Compression
Flowmeter, 0–200 CC. 65 mm
Fuse, 1A, 5 x 20, Antisurge
Fuse, 4A, 5 x 20, Antisurge
GLS, TOC Analyzers Bypass drain
Lamp Assembly, UV, TOC series
Membrane, Hydrophobic, 0.063 x 0.087
Nut, Flangeless,
1
/
8
-in. ETFE P354
O Ring; #009 Silicon, 70 DURO
O-Ring, #013 Silicone, 70 DURO
O-Ring,#012, Silicon, 70 DURO
Plug, ¼–28
Switch, Pressure, 15–60 PSI, Manifold
Tubing PFA,
1
/
8
-in. OD x 0.062-in. ID
Tubing, PFTE,
1
/
8
-in. OD x 0.030-in. ID
Union,
1
/
8
-in. MPT x
1
/
8
-in. T
Valve, 3-way, Burkert, 125 MAN
Valve, 3-way, Burkert, 127 MAN
Qty
4
1
12 feet
12 feet
5
1
1
10
2
2
2
1
4
2
1
1
1
2
2
4
1
1
10
12
10
10
2
1
8
8
12
Table 26 Fittings and O-ring kit
Description
Fittings and O-Rings Kit, TOC UV Analyzers, includes:
Barb Adaptor ¼–28 x 0.08
Qty
1
4
Item no.
014659
016183
026009
026067
014016
014458
014459
015806
020590
110131
021049
013848
020141
019507
020123
58492-00
58442-00
58441-00
013849
013861
013860H
020589
015804
200124
013830H
013829
013828
013827
013831
014038
018248
Item no.
200132
013830H
English 77
Table 26 Fittings and O-ring kit (continued)
Description
Barb Adaptor ¼–28 x 0.102 (13)
Barb Adaptor ¼–28 x 0.129 (14)
Barb Adaptor ¼–28x 0.164 (16)
Barb, Reducer
1
/
8
-in. x ¼-in. (16 x 24 mm)
Barb, Reducer
1
/
8
-in. x
3
/
16
-in. (16 x 15 mm)
Clamp, ½-in. NYL
Elbow,
1
/
8
-in. T x
1
/
8
-in. MP
Elbow, Compression
Elbow, Compression
Ferrule,
1
/
8
-in. SF, ETFE YEL P359X
Fitting 0.470 cable, water tight
Fitting, ¼-in. cable, water tight
Fitting, ¼-in. NPT male x ¼ barb
Fitting, ¼-in. T x ¼-in. NPT female
Fitting,
1
/
8
-in. NPT x
1
/
8
-in. T, Blank PP
Fitting,
5
/
16
-in. Cable, water tight
Fitting, Male Luer to
1
/
8
-in. Barb, PP
Fitting, Male Luer to
1
/
8
-in. NPT thread
Fitting, Tee Female Luer
Nut, Flangeless,
1
/
8
-in. (ETFE) P354
O Ring; #009 Silicon, 70 Duro
O-Ring, #013 Silicone, 70 Duro
O-Ring, 2-012,Silicon Rubber
O-Ring, #012,Silicon, 70 Duro
Plug, ¼–28
Rubber Disc
Union,
1
/
8
-in. MPT x
1
/
8
-in. T
Qty
2
5
5
5
2
1
1
10
5
2
10
5
2
5
4
4
10
2
2
5
10
4
4
4
10
10
5
Table 27 Kalrez O-ring kit
Description
Kit, Kalrez O-ring, includes:
Diaphragm, Simriz, Burkert
O-Ring, 009, Kalrez - 4079
O-Ring, 013, Kalrez - 4079
O-Ring, 6.1 mm x 1.6 mm X-S
Qty
5
1
1
1
3
78 English
Item no.
58492-00
58442-00
58441-00
013848
020141
019507
57857-00
020123
014659
019509
014016
013860H
013849
013946
013949
013832
013834
013858
013948
013829
013828
013827
013831
014038
010817
014084
013861
Item no.
6948600
6019100
6019200
6019500
6019800
Table 28 Bottle kit
Description
Bottle Kit, includes:
Carboy, 19 liter
Tubing, PFTE,
1
/
8
-in. OD x 0.03
Union,
1
/
8
-in. MPT x
1
/
8
-in. T
Bottle, one gallon
Weight, Reagent, PVC,
1
/
8
-in. NPT
Tubing PFA,
1
/
8
-in. OD x 0.062
Installation Drawing
Ferrule,
1
/
8
-in. SF, ETFE YEL P359X
Weight, Reagent, SST,
1
/
8
-in. NPT
Nut, Flangeless,
1
/
8
-in. ETFE P354
Reagent Storage Tray
Table 29 Miscellaneous kits
Description
Lamp Kit, Additional Retrofit
Level Detector Kit, Reagent and Enclosure Spill
Kit, Dual Stream Valve Assembly, TOC Analyzers
Kit, Dual Stream Valve Assembly, TOC Analyzers Retrofit
Kit, Retrofit, UV Power Supply
Kit, Threaded Plug
Kit, UV, Firmware upgrade HACH, Eng
Kit, Power Cord, TOC Analyzers
Kit, Network Interface Card, RS232
Kit, Network Interface Card, RS485/RS422
Qty
2
2
12
1
1
2
12
4
4
1
4
2
Table 30 Accessories
Description
Rack Assy, TOC
Gas Generator, TOC, 230/115V (requires clean dry instrument air)
Gas Generator, TOC, with 115V compressor
PS200, Blowback Filter, FM with 100 μm element
PS200, Blowback Filter, FM with 50 μm element
PS200, Blowback Filter, FM with 300 μm element
PS200, Blowback Filter, FM with 25 μm element
Item no.
200129
030501
026067
014016
030506
011622
026009
090201
013849
54838-00
013848
54131-00
Item no.
200127
200128
200136
200137
5004300
54137-00
5463200
58479-00
59200-00
59200-01
Item no.
120161
4300-0005
4300-0006
4200-1001
4200-1002
4200-1003
4200-1004
English 79
Table 30 Accessories (continued)
Description
Purge Gas generator Pneumatic AAS300
Kit, Dual Stream, FM
Z-PURGE, Analyzer left, CL1 DIV2, (requires 200130)
Z-PURGE, Analyzer top, CL1 DIV2, (requires 200130)
Z-PURGE, Wall Mount, CL1 DIV2, (requires 200130)
Kit, Pneumatic condenser cooler
Block, angled input, (Kynar) TOC Sample, DI
Manifold, valve (Kynar), TOC
Manifold top sparger (Kynar), TOC
Manifold bottom sparger (Kynar), TOC
Manifold, UV,1950PLUS, Kynar
Replacement pump kits
Pump kit 200117, 200118, 200120 and 5787000
Item no.
4300-0003
6023800
4000-0011
4000-0006
4000-0008
200130
011604-01
11582-01
11581-01
11583-01
11663
Kit
200117, left side of the analyzer
(Item no.)
200117, right side of the analyzer
(Item no.)
200118, left side of the analyzer
(Item no.)
200118, right side of the analyzer
(Item no.)
80 English
1 (head) 2 (tube) 3 (barbs) 4 (length)
254 mm (10 in.)
#13
(024505)
#13
(026043)
0.102 in.
(013829)
152.4 (6 in.)
5 (length)
152.4 (6 in.)
254 mm (10 in.)
#14
(024506)
#14
(026044)
0.129 in.
(013828)
152.4 mm (6 in.)
152.4 (6 in.)
152.4 (6 in.)
177.8 mm (7 in.)
Kit
200120, left side of the analyzer
(Item no.)
200120, right side of the analyzer
(Item no.)
200120, sparger waste pump installation
(Item no.)
5787000, right side of the analyzer
(Item no.)
1 (head) 2 (tube) 3 (barbs) 4 (length)
254 mm (10 in.)
#16
(024508)
#16
(026046)
0.164 in.
(013827)
#13
(024505)
0.160
(5742600)
0.102 in.
(013829)
Pump kits 200139 and 200141
152.4 (6 in.)
152.4 (6 in.)
5 (length)
152.4 (6 in.)
177.8 mm (7 in.)
152.4 (6 in.) 406.4 mm (16 in.)
152.4 (6 in.)
Kit
200139, left side of the analyzer
(Item no.)
200141, right side of the analyzer
(Item no.)
1 (head)
#14
(024506)
#14
(024506)
2 (tube)
Tube in Tube
(120240-02)
Tube in Tube
(120240-02)
3 (retainer)
0.75 in.
(026076)
0.75 in.
(026076)
4 (barbs)
0.08 in.
(013830H)
0.08 in.
(013830H)
English 81
Pump kit 5786700
Kit
5786700, right side of the analyzer
(Item no.)
1 (head) 2 (tube) 3 (barb) 4 (tube) 5 (barbs) 6 (length)
#24
(024538)
#24
(026071)
1
/
8
x ¼ in.
(013831)
#14
(026044)
0.129 in.
(013828)
25.4 mm
(1 in.)
7 (length)
127 mm
(5 in.)
8 (length)
279.4 mm
(11 in.)
Pump kits 200119, 200138, 200140, 200142 and 5414700
82 English
Kit
200119, left side of the analyzer
(Item no.)
200119, right side of the analyzer
(Item no.)
200138, left side of the analyzer
(Item no.)
200138, right side of the analyzer
(Item no.)
200140, left side of the analyzer
(Item no.)
200142, right side of the analyzer
(Item no.)
5414700, right side of the analyzer
(Item no.)
1 (head)
#15
(024507)
#24
(024538)
#24
(024538)
#15
(024507)
2 (tube)
#15
(026045)
#24
(026071)
#24
(026071)
#15
(026045)
1
1
1
1
3 (barb)
/
8
x
3
/
16
in.
(014038)
(013831)
/
/
8
8
x ¼ in.
x ¼ in.
(013831)
/
8
x
3
/
16
in.
(014038)
4 (tube)
#14
(026044)
#14
(026044)
#14
(026044)
#14
(026044)
5 (barbs)
0.129 in.
(013828)
0.129 in.
(013828)
0.129 in.
(013828)
0.129 in.
(013828)
#16
(024508)
#16
(026046)
1
/
16
x
1
/
8
in.
(5410600)
#14
(026044)
0.129 in.
(013828)
6 (length)
25.4 mm
(1 in.)
25.4 mm
(1 in.)
25.4 mm
(1 in.)
25.4 mm
(1 in.)
25.4 mm
(1 in.)
7 (length)
228.6 mm
(9 in.)
152.4 mm
(6 in.)
228.6 mm
(9 in.)
152.4 mm
(6 in.)
215.9 mm
(8.5 in.)
127 mm
(5 in.)
152.4 mm
(6 in.)
8 (length)
152.4 mm
(6 in.)
127 mm
(5 in.)
152.4 mm
(6 in.)
127 mm
(5 in.)
127 mm
(5 in.)
139.7 mm
(5.5 in.)
127 mm
(5 in.)
Appendix
Hardware configuration
Table 31 shows the hardware configuration of each analyzer, the replacement pump kits and the IR
ranges and flow rates. Pump flow rates are all calculated for 60 Hz. Refer to
on page 26 and Prepare the persulfate solution on page 27 for the molarity values for the
acid and persulfate pump.
Table 31 Hardware configuration
4195- and 6195-
TOC range, mg/L
Number of reactors
IR span, ppm CO
2
IR, ppm CO
2
maximum
Sample pump size
(Item no.)
Flow, mL/minute
1010/
3010
5
1
1
1000
950
15
(200119)
10.2
1020/
3020
10
1
1
1000
950
1030/
3030
25
1
1
1000
950
1040/
3040
50
1
1
1000
950
1050/
3050
100 dilution
1
1
1000
950
15
(200119)
15
(200119)
16
(200120)
14
(200118)
10.2 10.2 4.8 1.26
1060/
3060
200 dilution
1
1000
950
1070/
3070
500 dilution
1
1000
950
14
(200118)
14
(200118)
2000/
4000
100
2
10000
9500
15
(200119)
1.26 1.26 10.2
English 83
4195- and 6195-
Table 31 Hardware configuration (continued)
1010/
3010
1020/
3020
13
(200117)
13
(200117)
1030/
3030
1040/
3040
13
(200117)
13
(200117)
1050/
3050
13
(200117)
1060/
3060
1070/
3070
13
(200117)
13
(200117)
2000/
4000
13
(200117)
Acid pump size
(Item no.)
Flow, mL/minute
Dilution pump size
(Item no.)
Flow, mL/minute
RPM
Resample pump size
(Item no.)
Flow, mL/minute
Persulfate pump size
(Item no.)
Flow, mL/minute
RPM
0.36
—
—
6
24
(200138)
5.6
13
(200117)
0.12
2
0.36
—
—
6
24
(200138)
5.6
13
(200117)
0.12
2
1
H-6195-xxxx analyzers all have two reactors.
0.36
—
0.36
—
0.36
15
(200119)
—
6
15
(200119)
—
6
16
(200120)
3.4
13
(200117)
0.12
2
1.6
13
(200117)
0.12
2
10.2
6
24
(200138)
5.6
13
(200117)
0.12
2
0.36
15
(200119)
0.36
15
(200119)
0.36
—
10.2
6
15
(200119)
10.2
6
16
(200120)
3.4
13
(200117)
0.12
2
1.6
13
(200117)
0.12
2
—
6
15
(200119)
3.4
14
(200118)
0.42
2
4195-
TOC range, mg/L
Number of reactors
IR span, ppm CO
2
IR, ppm CO
2
maximum
Sample pump size
(Item no.)
Flow, mL/minute
Acid pump size
(Item no.)
Flow, mL/minute
Dilution pump size
(Item no.)
Flow, mL/minute
RPM
Resample pump size
(Item no.)
Flow, mL/minute
Persulfate pump size
(Item no.)
2010/
4010
200
2020/
4020
500
2
10000
9500
15
(200119)
10.2
2
10000
9500
16
(200120)
4.8
13
(200117)
13
(200117)
0.36
—
0.36
—
—
6
—
6
15
(200119)
16
(200120)
3.4
14
(200118)
1.6
14
(200118)
2030/
4030
1000
2
10000
9500
16
(200120)
4.8
2040/
4040
1000 dilution
2
10000
9500
2050/
4050
2000 dilution
2
10000
9500
14
(200118)
1.26
14
(200118)
1.26
13
(200117)
0.36
—
13
(200117)
0.36
—
6
15
(200119)
10.2
6
13
(200117)
0.36
15
(200119)
10.2
14
(200118)
15
(200119)
6
15
(200119)
0.42
14
(200118)
3.4
14
(200118)
3.4
14
(200118)
2060/
4060
5000 dilution
2
10000
9500
2070/
4070
10000 dilution
2
10000
9500
14
(200118)
1.26
14
(200118)
1.26
2080/
4080
20000 dilution
2
10000
9500
14
(200118)
1.26
13
(200117)
0.36
24
(200138)
16.8
6
16
(200120)
1.6
14
(200118)
13
(200117)
0.36
15
(200119)
10.2
6
14
(200118)
0.42
14
(200118)
13
(200117)
0.36
24
(200138)
16.8
6
14
(200118)
0.42
14
(200118)
84 English
4195-
Flow, mL/minute
RPM
2010/
4010
0.42
2
2020/
4020
0.42
2
2030/
4030
0.42
2
2040/
4040
0.42
2
2050/
4050
0.42
2
2060/
4060
0.42
2
2070/
4070
0.42
2
2080/
4080
0.42
2
4195-
TOC range, ug/L
Number of reactors
IR span, ppm CO
2
Sample pump size
(Item no.)
Flow, mL/minute
Acid pump size
(Item no.)
Flow, mL/minute
Resample pump size
(Item no.)
Flow, mL/minute
Persulfate pump size
(Item no.)
Flow, mL/minute
Sparger waste pump size
(replacement kit)
Flow, mL/minute
RPM
Response time T90 at 60 Hz
1002/3002
2000
2
20
14
3
0.18
0.18
—
0
6
< 5
1
1000
24
2
(200140)
(200139)
15
(200142)
11.7
14
3
(200141)
1005/3005
5000
2
1000
1
24
2
(200140)
20
14
3
(200139)
0.18
15
(200142)
11.7
14
3
(200141)
0.18
—
0
6
< 5
1006/3006
10000
1
2
1000
24
2
(200140)
20
14
3
(200139)
0.18
16
2
(5414700)
4.8
14
3
(200141)
0.18
16
(200120)
4.8
6
< 5
1007/3007
25000
1
2
10000
24
2
(200140)
20
14
3
(200139)
0.18
16
2
(5414700)
4.8
14
3
(200141)
0.18
16
(200120)
4.8
6
< 5
1008/3008
50000
1
2
10000
24
2
(200140)
20
14
3
(200139)
0.18
16
2
(5414700)
4.8
14
3
(200141)
0.18
16
(200120)
4.8
6
< 5
1
2
3
If a different TOC range is selected, the same range may result even if shown in different units (i.e.,
2.000 mg/L can be shown as 2000 μg/L).
Represents the size of the pump head and pump tube. Use a barb adapter outside the pump head body to decrease to 14 to get the published response time.
Tube-in-tube assembly used, not 14 tubing.
CSV output
Note: (CH1) and (CH2) are shown in
to show how the analog channels (CH1 and CH2) are set. In the table, CH1 is set to a TOC reading (latched, zeroed or live) and CH2 is set to Fault ID.
Table 32 CSV data format
Status Fault
ID
Faults EOL Date
MM/DD/YY
1
Time
00:00:00
Stream
0
CO
2 ppm
Rate of change
1
The date format depends on the user settings.
TOC (CH1) Fault
ID
(CH2)
0000 ± 00000 0000.000 0 0 0 00 LFCR
English 85
18
19
20
21
22
10
11
12–16
17
6
7
8
9
2
3
4
5
ID in the CSV output
1
6
7
8
ID
5
5
6
7
8
2
3
4
Value
1
Description
Online
Online
Online
Offline
Offline
Cleaning
Cleaning
Cleaning
Table 33 Status values in the CSV output
13
14
15
Value
9
10
11
12
Description
Pre zero period
Pre zero period
Baseline determination
Baseline determination
Baseline determination
Pre span period
Pre span period
Table 34 Fault ID codes in the CSV output
Description
Online
Offline, purge cycle, cleaning, calibration, or in the Service screens
Maintenance event
Fault event
20
21
22
Value
16
17
18
19
Description
Span determination
Span determination
Span determination
Purging
Purging
Purging
Purging
Table 35 Fault/Maintenance event codes
Description
Zero stability
Zero standard level
Span stability
Span standard level
Maintenance %
Validation %
Calibration failure
Reactor flow
Low reagents
Low cell temperature
Spill detection
Not used
No sparger flow
No UV lamp flow
No carrier gas
Drain level
Not used
Reactor flow
F02
F03
F04
F05
F06
M10
M11
M12–M16
F01
M06
M07
M08
M09
ID on the main screen
M01
M02
M03
M04
M05
86 English
ID in the CSV output
23
24
25
26–32
Table 35 Fault/Maintenance event codes (continued)
Description
Not used
Not used
IR detector
Not used
ID on the main screen
F07
F08
F09
F10–F16
I/O board components
Figure 23 8001 I/O board components
1 NDIR cell heater light
2 Sparger flow bubble detector light
3 UV flow bubble detector light
Table 36 Internal indicator lights
Light
NDIR cell heater light
Description
Flashes during a heat cycle.
Sparger flow bubble detector light Flashes when the sparger flow bubble detector senses bubbles at the sparger inlet.
UV flow bubble detector light Flashes when the UV flow bubble detector senses bubbles at the UV block.
English 87
88 English
HACH COMPANY World Headquarters
P.O. Box 389, Loveland, CO 80539-0389 U.S.A.
Tel. (970) 669-3050
(800) 227-4224 (U.S.A. only)
Fax (970) 669-2932 [email protected]
www.hach.com
HACH LANGE GMBH
Willstätterstraße 11
D-40549 Düsseldorf, Germany
Tel. +49 (0) 2 11 52 88-320
Fax +49 (0) 2 11 52 88-210 [email protected]
www.hach-lange.de
HACH LANGE Sàrl
6, route de Compois
1222 Vésenaz
SWITZERLAND
Tel. +41 22 594 6400
Fax +41 22 594 6499
©
Hach Company/Hach Lange GmbH, 2012. All rights reserved. Printed in U.S.A.
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