Metrohm 7010 TOC User Manual

7010 TOC ANALYZER - USER MANUAL

Version: 1.12

Prepared: DC

Verified : FG

Checked: FS

Approved: DM

Issued: 28/09/2015

I N D E X

7010 TOC ANALYZER - USER MANUAL

1 SAFETY PRECAUTIONS AND HAZARDS

1.1 General informations

1.2 List of warnings and potential dangers

1.3 Vent waste gas

1.4 Sample

1.5 UV lamps disposal

1.6 Analyzer general hazards

1.6.1 Electrical precautions and hazards

1.6.2 Operating precautions and hazards

1.6.3 Chemical and waste gas hazards

2 INTRODUCTION

2.1 Analyzer description

2.2 Applications

2.3 Fast Loop Reservoir

2.4 Liquid enclosure components

2.4.1 Peristaltic pumps

6 7 9 9

9 10 10

11 12

16 19

2.4.2 Scrubber

2.4.3 UV reactor (UVR) + UV Scrubber

2.4.4 U-Tube

2.4.5 Glass condenser

2.4.6 Dryer

2.4.7 By-pass Valve

2.5 Electrical enclosure components

2.5.1 Copper filter

2.5.2 Sodalime filter

22 22 23 23 24 24

26 26

7010 TOC ANALYZER - USER MANUAL

2.5.3 Pump motor

2.5.4 Air compressors

2.5.5 Pressure regulator , capillary and flowmeter

2.5.6 NDIR

2.5.7 User connections

3 INSTALLATION

3.0 Unpacking and inspecting

3.1 Analyser moving

3.2 Location and mounting instruction

3.3 PRECOMMISSIONING

3.4 Electrical connections

3.4.1 AC Power connections

3.4.2 Analog output

connections

3.4.4 Relay A/B

3.4.5 Digital input/output

27 28 28 29 29

31 31 31

33 34

34 35 36

3.4.6 Levels

3.4.7 External dilu to r supply

3.4.8 Fuses

4 USER INTERFACE

4.0 User instructions

4.1 Main Page

4.2 Main page + process values

4.3 Calibration page

37 37 37

41 42 45 46

7010 TOC ANALYZER - USER MANUAL

4.3.1 Zerogas

4.3.2 Liquid Zero

4.3.3 Manual Calibration

4.3.4 Run autocal

4.4 Timing page

4.5 General setup page

4.6 Datalogger pag

4.7 Dual stream configuration

4.8 Dual range option

5 MAINTENANCE

5.1 Pump tubing replacement

5.2 Copper wool replacement

5.3 Sodalime replacement in sodalime filter

5.4 UVR tubing's connection replacement

5.5 UV lamps replacements

5.6 Fuses replacement

47 48 49 50 51 52 53 55 56

61 63 64 65 66 67

6 PREPARATION OF THE CHEMICALS

6.1 Preparation of the TOC standard solution

6.2 Preparation of the COD standard solution

6.3 Preparation of the Persulphate solution

6.4 Preparation of the Acid solution

6.5 Preparation of reducing solution

6.6 Preparation of the Cleaning solution

6.7 Preparation of TC Reagent solution

7 ANALYZER SHUT DOWN

APPENDIX Optional Configurations

69 70 71 72 73 74 75

1.0 SAFETY PRECAUTIONS AND HAZARDS

1.1 General informations

7010 TOC ANALYZER - USER MANUAL

Metrohm Applikon

operators of analyzer must be sure to read and observe the following instructions and to apply all national or local regulations and laws regarding health and safety of the workfare.

Use, maintenan ce and service of this analyser are allowed only by qualified personnel fully trained on the analyzer’s operation. This personnel should be physically and mentally fit and not under the effect of alcohol or/and drugs. When the analyzer is not used it should be protected from intentional or unintentional powering on, using a proper circuit breaker.

Before to proceed with analyzer installation, please read through and fully understand this instruction manual to ensure proper operation. Pay attention to all caution and dangers labels present on the analyzer and all caution and danger statements written in this manual. For analyzer installation and use, please refer carefully to all information and recommendations present in this manual. Failure to do so and non-observance of hazard or danger warnings could result in death or serious inju ry to the operators or damage to the analyzer.

Before to use the analyser is necessary to check visually for damage of safety devices and report to your reference head even if they don’t cause analyzer stop or malfunction. All analyzer components are installed inside two metallic enclosures with doors equipped with a special key for opening, only endowed qualified maintenance personnel. (ref. section 3.3). Opening the door for visual inspection is possible while the analyser is in normal operation, but only if all the safet y precautions and hazard and danger labels have been strictly observed.

shall not be liable for errors contained herein and/or for any incorrect use of the analyser. The department head and the

7010 TOC ANALYZER - USER MANUAL

1.2 List of warnings and potential dangers

The table below is a list of hazard and danger warning labels that is possible to find on the analyzer and/or in this manual. In the case of these labels, becoming damaged or unreadable they should be replaced with new ones by the analyzer owner.

Tab. 1-1: List of hazards and dangers

Hazard of eletrical shock

This symbol is used to warn of a hazard of severe electric shock or electrocution. All controls and maintenance on electrical devices labelled with this symbol should be made by qualified personnel in accordance with national or local regulations. Qualified personnel means a person who has been fully trained and has professional experience to avoid electrical hazards and dangers. To avoid potential fatal electrical shock and/or analyzer damage always disconnect input power to analyzer before servicing.

Hazard of chemical burns

This symbol is used t o warn of a hazard of severe burns and seroius injury from dangerous chemicals. All handling and manipulations during operation and maintenance of chemicals labelled with this symbol should be made by qualified personnel in accordance with national or local regulations. Qualified personnel means a person who has been fully trained and has professional experience to avoid chemical hazards and dangers. Before to proceed with the handling of chemicals or operations read the material safety data sheets supplied with each chemical to ensure all the necessary precautions are taken.

Hazard of UV radiation

This symbol is used to warn of an hazard of ultraviolet radiation. It is obligatory to wear eye protection to operate with the UV lamps labelled with this symbol. Never look directly at a lighted UV lamp. UV radiation exposure can cause severe and permanent damage to skin and eyes.

Concerned parts:

Fans Air compressors UV power supplies Main power supply UV lamps Pump motors Input terminal

Corcerned parts:

Liquids enclosure Reagents containers

Concerned parts:

UV lamps

Hazard of thermic shock and burns

This symbol is used to warn of an hazard of t hermic shock and burns. Some parts of the analyzer become extremely hot during analyzer normal operations. Avoid skin contact with these surfaces and if necessary to service these parts be sure to sufficiently enough to avoid burning. Always disconnect input power to analyzer before servicing these parts.

Warning of general hazard

This symbol means that is necessary read this manual before proceeding with any service operation to know exactly how to operate in a proper way. Only qualified personnel or personnel fully trained on analyzer use and maintenance is allowed to proceed with service operations on the unit.

Corcerned parts:

UV lamps Pump motors Air compressor

Concerned parts:

TOC analyzer

7010 TOC ANALYZER - USER MANUAL

1.3 Vent waste gas

Waste gases coming from analyzer oxidation process depend on th e user’s sample composition. They are labelled on the external side of the cabinet as VENT outlets. It is necessary to connect an extension tubing or to provi de for safe venting to the atmosphere or to a classified safe area.

1.4 Sample

Take appropriate precautions to avoid direct contact with sample stream. It is responsability of the user to be aware of and take all precautions regarding physical, chemical, radiation and/or biological hazards and dangers coming from sample stream and/or sample vapours. It is also responsibility of the user to be aware of potential hazards regarding the chemical and physical compat ibi lit y of sample stream with the analyzer materials.

1.5 UV lamps disposal

Used or replaced UV lamps contain a small quantity of mercury and they must be disposed according with national or local environmental regulations regardin g hazardous and poisonus materials.

Table 1-2 : List of materials used in 7010 TOC Analyzer

Pump tubings Fittings Connection tu bings GLS,U Tube, Scrubber, Condenser Halogens and sodalime filter body Filter cont ent s

UV lamps Bypass valve IR cell Gas dryer tubing

Norprene,Tygon Polypropylene PFA Glass

PVC, p olycarbon at e Copper wool (halogens filter), Sodalime (CO2 filter) Quartz Noryl, viton Stainless st eel Nafion

1.6 ANALYZER GENERAL HAZARDS

1.6.1 Electrical precautions and hazards

7010 TOC ANALYZER - USER MANUAL

In all electrical devices that are 230 VAC (or 115 VAC opt.) powered present hazards of electrical shock or electrocution. To protect all the personnel involved in analyzer use and maintenance, the doors of the two analyser enclosures are equipped with a special key for opening.

If necessary to operate inside the electrical enclosure with the analyzer powered on, please consider th at this operation must be made only by qualified personnel in accordance with national or local regulations. Qualified personnel means a person who has been fully trained and has professional experience to avoid electricity hazards and dangers.

Service qualif ied personnel will receive the special key to open the electrical enclosure.

Before to service the analyzer or parts of that electrically powered, turn off all power to avoid risk of electrocut ion.

To turn off power from an electrical device is necessary to interrupt the power line using a circuit breaker or an isolating switch to be sure that there is no power in the area being serviced.

Users and qualified maintenance personnels must proceed as follows:

pay attent ion to electrical shock and/or electrocutions labels placed on the analyser always isolate power before servicing the analyser

In case of loss of power the analyser stops and will automaticall y restart as soon as power is restored.

WARNING: UV lamp power supply reaches an ignition voltage up to 3000 volts; do not operate any service activity without removing the instrument power cord

Analyser’s control circuitry is powered 24 Vdc and 12 Vdc. Inside the electrical enclosure the lower level of protection against direct contacts is IP2X. Analyzer enclosures are IP54 (because of air fans holes).

Protection against indirect contacts is guaranteed by efficient grounding of all isolated metal masses. Grounding bar is located inside the electrical enclosure, in upper left position below the protection cover.

It will be user’s responsability to check and garantee periodically the perfect efficiency of analyzer’s grounding.

1.6.2 Operating precautions and hazards

7010 TOC ANALYZER - USER MANUAL

HAZARD:

PREVENTIVE ACTIONS:

HAZARD:

PREVENTIVE ACTIONS:

HAZARD:

PREVENTIVE ACTIONS:

Mechanical hazards caused by moving parts such as fans, pumps, motors and air compressors

To avoid risks the analyzer’s moving parts have been designed, built and located in a closed enclosure with a special opening key. Where present inside the enclosures, these parts have protection covers to avoid any contact and physical injury to users.

Hazards of burns caused by hot parts of UV lamps, motors and air compressors

To avoid risks, the analyser’s parts that become very hot to the touch have been designed, built and located in closed enclosure with a special opening key. When present inside the enclosures, these parts have protection covers and warning labels to avoid any contact and physical injury to users.

Hazard of poisoning caused by waste gas coming out from VENT line

Install t he analyser in location of adequate dimensions and well ventilated.

HAZARD:

PREVENTIVE ACTIONS:

Hazards of UV radiation exposure caused by UV lamps

To avoid risks, the analyser’s parts that produce UV radiation emissions have been designed, built and located in closed enclosure with a special opening key. When present inside the enclosures, these parts have protection covers and warning labels to avoid any contact and/or exposure and/or physical injury to users.

7010 TOC ANALYZER - USER MANUAL

HAZARD:

PREVENTIVE ACTIONS:

HAZARD:

PREVENTIVE ACTIONS:

Hazard of electric shock and/or electrocution in the electrical enclosure

The analyser’s electric equipment complies with

EN 60204

To avoid risks, the analyser’s parts that can cause hazard of electric shock and/or electrocution have been designed, built and located in a closed enclosure with a special opening key. When present inside the enclosures, these parts have protection covers and warning labels to avoid any contact and serious injury or death to users.

Hazard of burns and poisoning caused by contact with dangerous chemicals

To avoid risks, the analyser ’s parts that can cause contact wit h chemicals have been designed, built and locat ed in closed enclosure with a special opening key. Before to service the liquids enclosure, read the material safety data sheets supplied with each chemical to t ake all the necessary precautions when handling. Wear eye protections, gloves, mask and protective clothing if necessary.

requirements.

Electrical equipments of input power and grounding must comply the national or local regulations and laws. Check that the source voltage to be used corresponds with that requested by the analyser.

Check periodically the power cord as well as the analyser grounding.

WARNING:

voltage up to 3000 Volts; do not undertake any service activity without removing the instrument power cord.

NOTE :

UV lamp power supply reaches an ignition

1.6.3 Chemical and waste gas hazards

The analyser has been designed, built and equipped to avoid risks caused by physical and chemical factors as noise, vibrations, radiations, dust, waste gas etc.

2.0 ANALYZER DESCRIPTION

This manual provides general information regarding the principle of operation and proper installation and operation of the 7010 TOC A nal yser . The analyser measures Total Organic Carbon in liquid samples using the EPA approved method based on UV persulfate oxidation and detection of generated carbon dioxide using a Non Dispersive Infrared analyser. This method meets also the requirements of European ISO/CEN guidelines. The analyser provides this measurements on liquid samples ranging from 0-5

7010 TOC ANALYZER - USER MANUAL

mg/l to 0-20000 mg/l. The analyser conforms to EPA, DIN, CE, AST M and NAMUR regulations.

2.1 APPLICATIONS

The

701 0 TOC

(TOC) in water. It has been designed for the following applications:

Industrial wast e water

Condensate and cooling water

Drinking and river water

analyser continuously measures Total Organic Carbon

7010 TOC ANALYZER - USER MANUAL

Industrial wat er treatment plant inlet/outlet

For different applications or different aqueous matrices it is recommended to contact your Metrohm distributor to verify your application with our specialists.

7010 TOC ANALYZER - USER MANUAL

The analyser is assembled in two separated enclosures. The first one, called

LIQUIDS enclosure

, includes all the components involved in sample and reagent flows as well as

their mixing in sparging and oxidation stages. This enclosure is properly vented by a fan to allow good air refreshment inside the cabinet. The second one, called

enclosure

, includes the main power supply, the carrier gas generation and flow adjustment devices, the controlleing PCB assembly and the infrared detector.

legend:

01)

UV lamp power supplies

02) glass condenser

03) by-pass valve

04) condenser fan

05) dryer tubing

06) UV reactor

07) resample pump

08) sample pump

09) persulfate pump

10)

phosphoric acid pump

11) auto pump

12) UV scrubber

13) U-tube

14) scrubber

15) drain

ELECTRICAL

legend:

01) user connections

02) copper filter

03) pumps motor

04) pressure regulator +

flow capillary

05) sodalime filter

06) dryer + scrubber

capillary

07) flowmeter

08) check valve

09)

carrier gas compressor

10) scrubber gas

compressor

11) fan

12) air filter

13) NDIR

2.2 OPERATING PRINCIPLE

SODIUM PERSULFATE CLEANING ACID SAMPLE

The water from the sample source (directly from the sampling point or through the optional filtration unit) is fed to a sampling device mounted on the external left side of the analyzer

(ref. page 1 9)

to check the sample presence. This device allows a good sample refreshment and will put the analyzer in stand-by condition in case of loss of sample.

. This device drains the sample excess and is equipped with a level sensor

7010 TOC ANALYZER - USER MANUAL

The sample is pumped by a peristaltic pump afterd mixing with acid (usually phosphoric acid) pumped by a second peristaltic pump

(1 0)

. The inorganic removal is performed using ambient air provided by an internal air compressor carbon carbonates to carbon dioxide. The carbon dioxide dissolved in water is then driven out by the sample to the vent using compressed air.

The acidified and sparged sample is then pumped from the scrubber bottom to the UV reactor agent (usually sodium persulfate) pumped by a dedicated peristaltic pump

The presence of a strong oxidizing agent combined with high level UV radiation causes the oxidation of organic compounds. The produced carbon dioxide is driven to the gas-liquid separator that containing carbon dioxide goes to the infrared analyser sequence through a glass condenser filter

(02)

the stainless cell of the IR. The carrier gas used for the oxidation and detection stages is generated by a second internal a ir compressor through a sodalime filter pressure regulat or finally the UV reactor. All these devices are necessary to guarantee high precision and stability of carrier gas flow as well as to control and be able to display the flow.

(1 0)

. This first process lowers the pH of the sample and convert the

(06)

by the resample pump

(1 2)

. The liquid sample is drained off while the air

(02)

. These devices are present to prevent condensation and corrosion inside

(05)

. The carbon dioxide free gas passes through a

(04)

, a capillary tubing and a digital flowmeter

(08)

to the inorganic scrubber

(07)

, after mixing with a strong oxidizing

(1 3)

, passing in

, gas drier tubing

(05)

and a halogens

(09)

and is passed

(08)

(1 4)

(09)

to reach

SODIUM PERSULFATE CLEANING ACID SAMPLE

TOC FLOW DIAGRAM

7010 TOC ANALYZER - USER MANUAL

legend:

01)

UV lamp power supplies

02) glass condenser

03)by-pass valve

04) condenser fan

05) dryer tubing

06) UV reactor

07) resample pump

08) sample pump

7010 TOC ANALYZER - USER MANUAL

REDUCING REAGENT FLOW D I AGRAM

09) persulfate pump

10)

phosphoric acid pump

11) auto pump

12) UV scrubber

13) U-tube

14) scrubber

15) drain

X2)

reducing reagent pump

SODIUM PERSULFATE CLEANING ACID SAMPLE REDUCING REAGENT

2.3 FAST LOOP RESERVOIR

7010 TOC ANALYZER - USER MANUAL

The external reservoir allows a fast circulation of the sample coming f rom the sampling point or from the optional filtration unit. Inside the fast-loop reservoir the sample is at atmospheric pressure and this allows the sample pump to function with a constant delivery and no overpressure.In addition, the fast-loop reservoir is a usef ul extra quantity of sample to avoid wrong alarms in case of a short loss of sample as well as eliminating air bubbles coming from the sample line or from t he cleaning cycle of the optional filtration unit. The stainless steel drain tubing keeps a constant water level inside the container and allows a proper sample circulation to avoid suspended solids accumulation.

The sample flow should be adjusted to have a constant sample overflow through the stainless steel tube. Up to 3 level switches can be connected to the analyzer, e.g. Stream A,Stream B and dilution water. Two of the switches are normally connected to the terminals that are foun d at the left hand side of the analyzer. For a dual stream analyzer where dilution water is also required for one or both streams, the third level switch is connected to the user connection inside the analyzer (see page 37).

For a single stream analyzer, in the even t of a missing sample or dilution water stream for a period longer than a preset time (normally set on installation to 30 s), an ala rm - LOSS OF SAMPLE - is triggered and the analyzer switches to Standby. When the missing sample or dilution water stream is reestablished, the analyzer restartsautomatically with a conditioning cycle.

In the case of a dual stream configuration, if no Stream A is present then the analyzer will continue to work only on Stream B until Stream A is reestablished, and vice-versa. If both streams are not present then again the alarm LOSS OF SAMPLE is triggered and the analyzer switches to Standby. If either or both streams are being diluted and the dilution water stream is missing, then jumpers found alongside the internal Level 3 terminal can be used to make the analyzer work only on the undiluted stream or switch to Standby if both streams are diluted, again giving the alarm LOSS OF SAMPLE.

7010 TOC ANALYZER - USER MANUAL

LIQUID ENCLOSURE

7010 TOC ANALYZER - USER MANUAL

2.4.1 PERISTALTIC PUMPS

In normal on-line conditions t he 7010 TOC analyser uses two pump motors with two pump heads driven by each motor. An extra pump head driven by a specific motor is used just in autocalibration, autovalidation or autocleaning cycles.

The sample pump head shown in flow diagram as closest to the motor. It pumps the sample from the external reservoir to the T fitting connected on the other side to the phosphoric acid pump head. Optimizing the sample pump flowrate is important to have a representative sample and to reduce the analyser response time.

The phosphoric acid pump head It pumps phosphoric acid from the phosphoric acid container to the T fitting connected to sample pump head acid addition to the sample is necessary to lower the sample pH and to remove the inorganic carbon (IC) by gas sparging.

The resample pump head the acidified and sparged sample from the bottom of the scrubber gas coming from the air compressor

The persulfate pump head sodium persulfate from the persulfate container to the UV reactor coming from the resample pump

(1 0)

is driven by the M2 motor and is located in the middle position,closest to the motor.

(07)

is driven by the M1 motor and is located in the upper position, UV lamps side. It pumps

(09)

and directed to UV reactor

(09)

is driver by the M2 motor and is located in the middle position, UV lamps side. It pumps

(07)

and after is directed to UV reactor

(08)

is driven by the M1 motor and is located in the upper position,

(1 4)

to the T connection where it mixes with the carrier

(06)

, adding it to the mixture of sample and carrier gas

(06)

(08)

(1 0)

. The

The auto pump head shown in flow diagram as standard solution or the cleaning solution from its container to the analysis circuit when requested by the user or when programmed as autocal/val/clean cycle. The auto pump flowrate is higher than sample pump flowrate. This means that in case of an autocleaning cycle a portion of the cleaning solution will be driven towards the sample inlet, cleaning the sampling point.

(11 )

is driven by the M3 motor. It pumps the calibration/validation

2.4.2 SCRUBBER

7010 TOC ANALYZER - USER MANUAL

The scrubber It is a glass cylinder with the acidified sample inlet in upper right position. The acidified sample passes down by gravity through the scrubber and it’s sparged by the carrier gas coming from air compressor position. The carbon dioxide coming from the inorganic carbon present in the sample is sparged by the carrier gas flow and removed from the sample through the vent/drain tubing connected to the straight upper position of the scrubber. As a result, the sample at the scrubber bottom is IC free and it can be pumped by resample pump stage.

2.4.3 UV REACTOR + UV SCRUBBER

The UV reactor The reaction of oxidation is catalyzed by UV radiat ion with decomposition of sodium persulfate and creation of strongly oxidizing radicals. These conditions ensure the best recovery of organics present in the sample.

The second UV lamp is connected to UV scrubber inside this device.

(1 2)

is located in a vertical position near the peristaltic pumps.

(06)

is located on the left side of liquids enclosure. It consists of two high energy UV lamps.

(1 2)

. The oxidized sample at the UV lamps is sparged

(1 0)

, connected in the lower right

(07)

to the oxidation

2.4.4 U-TUBE

7010 TOC ANALYZER - USER MANUAL

2.4.5 GLASS CONDENSER

The U-Tube inlet and two outlet points. It separates the analyzed liquid part of the sample coming from UV reactor from the gaseous stream direct ed to the infrared analyser. It also drains the exausted sample and vents the sparging gas coming from the top of the scrubber. The gas mixture coming from the oxidation stage is driven by the carrier gas to the drying devices through the upper right outlet of the gas-liquid separator, towards to the glass condenser

The Glass condenser temperature difference between its glass body, cooled by a fan, and the hot treated sample coming from UV reactor.

(1 3)

is located in the middle position of liquids enclosure. It is a U shaped glass device, with two

(02)

is positioned between U tube and the by-pass valve. The glass condenser uses the

2.4.6 DRYER

7010 TOC ANALYZER - USER MANUAL

2.4.7 BY-PASS VALVE

The dryer concentric tubes. In the internal tubing flows the gas stream to dry. This tubing is water vapour permeable so that the humidity passes to the external tubing. In the external tubing there is a counter-current purge gas flow that removes the water vapour. The dryer prevents water condensation inside the IR cell

CAUTION : do not overtighten or twist gas dryer ends when installing or servicing, as this will restrict the airflow.

The By-pass valve shown in the diagram as It vents the gas stream avoiding it to flow through the IR cell when not strictly necessary.

(05)

is positioned between the BY-PASS VALVE and the IR detector. It consists of a coil of two

(03)

is activated during conditioning and cleaning phases.

7010 TOC ANALYZER - USER MANUAL

ELECTRICAL ENCLOSURE

+ 56 hidden pages

Metrohm 7010 TOC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual