Metrohm 7010 TOC User Manual

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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

2.5.1 COPPER FILTER

7010 TOC ANALYZER - USER MANUAL

2.5.2 SODALIME FILTER

The copper filter plastic container filled with copper wool. The gas leaving the dryer tubing is forced to go through this device to prevent corrosive effects due to gases like chlorine or chlorine dioxide that could be generated in the oxidation stage.

The sodalime filter and it absorbs the carbon dioxide from atmospheric air providing the analyzer with CO2 free air for its processes.

(02)

is located in the electrical enclosure immediately before the IR detector inlet. It is a

(05)

is located on the left side of electrical enclosure. It’s a plastic container full of sodalime

2.5.3 PUMP MOTOR

7010 TOC ANALYZER - USER MANUAL

The pump motors

M1,M2

and

are positioned in the electrical enclosure, on the left side. They drive multiple pump heads that move the sample and reagents throug h the different analyser t reat ment stages. Depending on the configurations there will be from three to six pump heads.

Motor rev/min Position Driven pumps

M1 05-06 rpm upper sample

M2 1 rpm middle acid

Pump Head mL/rotation

14 0,21 16 0,8 15 1,7 24 2,8

resample

persulfate

optional reducing reagent

M3 10-12 rpm lower calibration

validation

cleaning

2.5.4 AIR COMPRESSORS

7010 TOC ANALYZER - USER MANUAL

2.5.5 PRESSURE REGULATOR

CAPILLARY AND FLOWMETER

The air compressors provides the sparging gas used in the scrubber and the counterflow gas in the dryer.The second compressor

(09)

provides the carrier gas for oxidation and detection stages. They eliminate the need for an external air

treatment system and for compressed air as a requested utility, this saving cost.

These devices the front and are used to they allow for a highly precise and reliable adjustment for the carrier gas flow.

(04)

(09)

and

(1 0)

are located on the lower side of the electrical enclosure. Compressor

(07)

are located in the central part of the electrical enclosure with a pressure gauge on

(1 0)

2.5.6 NDIR

7010 TOC ANALYZER - USER MANUAL

2.5.7 USER CONNECTIONS

The infrared analyser board fitted with a stainless steel cylinder (the IR cell). It’s a Non-Dispensive Infrared analyser (NDIR) with high stability and reliability. The measuring scale of IR is related to the range of

701 0 TOC

analyzer provides:

1 4-20 mA output (A01). (A second 4-20 mA output (A02) is available on dual channels analyzers). 2 relays (RELAY A - programmable and RELAY B - fault) 1 24 Vdc 1 digital input

(1 3)

is located in the higher part of the electrical enclosure, on the right side. It is a PCB

701 0 TOC

1 digital output 1 level 3 - additional contact RS485

7010 TOC ANALYZER - USER MANUAL

INSTALLATION

3.0 UNPACKING AND INSPECTING

The

701 0 TOC

performances di rect ly in our facilities and it’s delivered inside a wooden box. Before to proceed with analyser installation, it is recommended to check carefully that box and analyzer have not been damaged during transportation. Take extreme care during analyzer unpacking and moving.

analyzer is assembled and fully tested for proper

3.1 ANALYZER MOVING

Take extreme care when lifting or moving the analyzer, its weight is about 37 kg. Before t o move the analyzer it is recommended to empty manually the glass p art s of liquids enclosure using an appropriate plastic syringe and tubing.

7010 TOC ANALYZER - USER MANUAL

3.2 LOCATION AND MOUNTING INSTRUCTION

It is recommended to install the analyzer in a suitable position. The location must be clean, covered and properly enclosed to provide the analyser with good ventilation and low dust concentration. Operating environmental conditions are: temperature between 5 and 40° C at max 80% relative humidity. Due of chemicals and waste gases it is absolutely necessary to choose a well ventilat ed location for the analyzer.

The

701 0 TOC

wall or stainless steel support rack installation. Use 4 screws M8 to fix the analyzer.

The analyser should be mounted with the display at eye level for easier operation and access.

analyzer is supplied with four mounting brackets for

3.3 PRECOMMISSIONING

Liated below are key points that must be followed in order to have an ideal installation:

the installation site should be as near to the sampling point as possible to reduce delay in response time

the drain line should be properly dimensioned and positioned with downward slope to allow the draining of analysed sample and the overflow coming from the external fast-loop reservoir. ( If the optional filtration unit is present, the drain pipe should be dimensioned to drain also the sample coming out from filtration system fast-loop).

Clearance requirements for the analyzer should be 20 cm on either side and 100 cm on the front

7010 TOC ANALYZER - USER MANUAL

Sufficient space for two 10 liter containers and one 5 liter container should be provided beneath the ana lyzer; if necessary, the reagents containers should be positioned in a suitable receptacle in case of spills

Dedicated waste gas line should be provided for safe venting to the atmosphere unless installed in a well ventiled area of adequate dimensions.

ATTENTION: depending on the sample chemical composition, its oxidation can generate hazardous gases. In these cases it’s strictly necessary to provide a safety system to allow waste gases vent to the atmosphere

WARNING: the sample drain of the analyzer must be at ambient pressure with no restriction or counterpressure. Please verify that this condition has been strictly respected during installation.

3.4 ELECTRICAL CONNECTIONS

All electrical connections should be made by qualified personnel in accordance with nationa l or local codes and regulations.

Qualified Personnel means a person who has been fully trained and has professional experien ce to avoid electrical hazards and dangers.

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

A circuit breaker must be installed near the analyzer to allow easy isolation of power in case of electrical problems and every time it is necessary to service the analyzer.

7010 TOC ANALYZER - USER MANUAL

It will be user’s task to check and guarantee periodically the perfect functionality of the analyzer’s grounding.

To avoid potential fatal electrical shock and/or analyzer damage always disconnect input power to analyzer before servicing (disconnecting the 115 VAC - 230 VAC plug)

ALWAYS ISOLATE POWER BEFORE SERVICING

3.4.1 AC POWER CONNECTION

The

701 0 TOC

Hz power. I t is provided with 2 meter long power cord and European Schuko plug (ref. CEE 7/ VII re gulat ion). Optional configuration with 115 Vac power supply and US plug. The analyzer is delivered with the power cord wires are already connected to terminals AC section of

CONNECTIONS

AC power enters on the top side of the electrical compartments through the supplied power cord. All the connections must be made in accordance with national or local regulations. It is recommended that the analyzer has its own dedicated circuit with a circuit breaker or an isolating switch installed near the unit.

analyser is designed fo r operation with 230VAC, 50/60

USER

7010 TOC ANALYZER - USER MANUAL

3.4.2 ANALOG OUTPUT CONNECTIONS

The

701 0 TOC

outputs for analysis value. Wiring connections use a twisted-pair signal cable with shield connected to the A/01 or A/02 located right on top of electrical enclosure.

analyzer provides 2 optically isolated 4-20 mA analog

3.4.3 RELAY A/B

NO ALARM: C NC / ACTIVE ALARM: C NO

RELAY A function is programmable in the general setup page.

Here below the list of the possible functions:

online (relay activated when analyzer is online) offline (relay activated when analyzer is offline) loss of sample (relay activated in case of loss of sample alarm) result alarm (re lay activated in case of result higher than the programmed value) validation alarm (relay activated in case of validation alarm) reagent alarm (relay activated in case of reagent's alarm) calibration alarm (relay activated in case of calibration alarm)

7010 TOC ANALYZER - USER MANUAL

RELAY B is activated in case of fault alarm

Fault alarms occur if certain conditions arise that risk the analyzer giving incorrect results. T hey are as follows:

carrier gas flow too low reagent levels too low zero gas too high emergency stop activated

3.4.4 RS 485

MODBUS RTU CONNECTION GUIDE 7010 Toc

Baud Rate 9600 Data bits 8 Parity E Stop bit 1

Slave I.D. 1

Address format alias

150 32-bits float (CD-AB) result CH1 152 32-bits float (CD-AB) result CH2 154 16-bit unsigned analyser status

7010 TOC ANALYZER - USER MANUAL

RS 485 SETTINGS

PROTOCOL

VALUES

STATUS VALUES

Stand by 0 Conditioning (to drain) 3 Conditioning (purge detector) 4 Online 5 Zerogas 6 Zerogas 7 Auto Function 1 Stopped 8

3.4.5 DIGITAL INPUT/EXTRA RELAY

Digital input is a remote function available for the following features:

Start / Stop

Digital input ' s function is selectable by the user.

Extra Relay is used for external operations. (24V DC available) for powering external devices. This output may be configured for separate ON and pause periods. The ON period is configurable between 1 and 99 seconds, the pause period is configurable between 1 and 999 minutes.

3.4.6 LEVELS

Level switch terminals - level 1 and level 2 works with same logic as level switches left side connectors. Additional level 3 can be configured with jumpers in order to be associated to 1, 2 or 1 & 2. C is the common terminal.

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3.4.7 EXTERNAL DILUTOR SUPPLY

230/115 Vac for supplying power to the external dilutor. Functions when the analyzer is in Conditioning and On-line mode.

3.4.8 FUSES

The analyzer has 2 fuses.

Fuse F1 power supply fuse 3.15 A for 230 V version

4 A for the 115 V version

Fuse F2 IR detector/digital flowmeter 1.25 A

Before to proceed with analyzer start-up it is absolutely necessary to check that all the operations for a proper installation and reagents preparation have been properly carried out.

Please verify that all the suggestions and recommendations has been respected.

After t his double check, please proceed as follows:

Connect the sample line inlet tubing (or filtered sample outlet coming from optional filtration system) to the fast-loop reservoir installed on the left side of the 7010 TOC analyzer

Connect the drain fitting of the fast-loop reservoir to the waste line

Put the acid inlet tubing (red label) in the phosphoric acid container beneath the analyzer and check that it is correct by position at the bottom of the container

7010 TOC ANALYZER - USER MANUAL

Put the persulfate inlet tubing (white label) in the sodium persulfate container beneath the analyzer and checkthat it is correct by position at the bottom of the container

Put the cleaning (or calibration or validation) solution inlet tubing (green label) in the cleaning (or calibration or validation) solution container placed beneath the analyzer and check that it is correct by position at the bottom of the container

Connect the funnel beneath the analyzer is connected to the waste DRAIN line

Check sample presence in fast-loop reservoir and adjust the sample flowrate (suggested 100-500 ml / min)

Switch on power to the analyzer. External fans, microprocessor and infrared analyzer will start.

The analyzer will proceed as follows:

7010 TOC ANALYZER - USER MANUAL

if the analyzer has been previously shut off in operation but measurement and output signal are not still valid until the conditioni ng delay has expired.

if the analyzer has been previously shut off in press operation but measurement and output signal are not still valid until the conditi oning delay has expired.

In the next few following minutes it is necessary to check:

sample presence in the scrubber, sample presence in the gas-liquid separator.

free draining waste with no restriction of gas-liquid separator drain outlet. The drain tube must not be submerged and the exhausted sample must be carried out by gravity.

It is not recommended to proceed with a

IMPORTANT NOTE:

During analyzer’s initial start-up it is necessary to decide to confirm cleaning as the automatic option (programmed as default option) or change to validation or calibration.

ONLINE

button on the display. This forces t he analyzer to start immediately with a conditioning cycle. The analyzer is totally in

zerogas cycle

ONLINE

STANDBY

and a

calibration cycle

status, it will start immediately with a conditioning cycle. The analyzer is totally in

status, it will stay in

before leaving the analyzer in online status for 4/6 hours .

STANDBY

mode; to start the analyser it is necessary to

This selection depends on the user’s sample composition and characteristics. For dirty samples it is highly recommended to use the default selection to avoid dirt accumulation inside the analyzer. This change of selection can only be made by When one option between cleaning, calibration and validation is selected as desidered automatic function the remaining two will be automatically disabled.

Forex. : ifautocleaning is the automatic function enabled, autocalibration and autovalidation will be automatically disabled.

Metrohm Applikon

qualified personne l.

USER INTERFACE

7010 TOC ANALYZER - USER MANUAL

4.0 USER INSTRUCTIONS

The user interface consists of a touchscreen located on the front panel of the analyzer enclosure. All the output/input data, information, alarms and fault conditions are shown on the display while all the commands and settings may be entered into to the analyzer simply by pressing the touchscreen buttons.

4.1 MAIN PAGE

The main screen displays:

Date and time Analyzer's st at us (on-line, conditioning, stopped, loss of sample...) Login **** window (two levels of password)

On Line / standby buttons

7010 TOC ANALYZER - USER MANUAL

these commands to online operations or to stop the analyzer in stand-by condition.

Stopped but t on displays the status of the analyzer when it is stopped (reading only), it is possible to escape from Stopped pressing Online or Standby but t ons

The trend of analysis

It displays graphically the analyzer's value trend during time.

The name of the analysis (for example TOC, TC, COD,...); read only

The value of analysis. If the value is below 20, one decimal place will be displayed.

(min. press 2 secs)

(min. pres. 2 secs)

allows to force the analyzer

The main screen displays:

A result record is written every 3 min into the notepad that can be opened by touching the central result graph. In the notepad data from the current day is shown.

In the case of an alarm being generated by the analyzer details will appear as a moving message at the bottom of the screen.

The message will identify the type of the alarm and the time the alarm was activated.

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The message remains visible until the cause has been resolved

Pressing on Login the user select:

BASIC ADVANCED SERVICE

Pressing on **** the user can enter the 4 number passwords

BASIC

7010 TOC ANALYZER - USER MANUAL

ADVANCED password: 1111

(access to calibration, timing and datalogger pages)

SERVICE

Pressing on **** password: available from technicians/distributors (access to calibration, timing pages,general setup pages and datalogger)

Metrohm Applikon

4.2 MAIN PAGE + PROCESS VALUES

Simply by pressing on the main page it is possible to display the following information:

SAMPLE (OK / NO):

displays th e normal or lack of presence of sample in the fast-loop reservoir

RELAY A (OFF / ON):

displays the status of the relay A

OUT EXTRA RLY (OFF / ON):

displays the status of the external operation relay (refer to timing page for activation and programmation)

7010 TOC ANALYZER - USER MANUAL

CARRIER flow :

displays the carrier gas flow value through the digital flowmeter in cc/min

CO2 conc:

displays the carbon dioxide value in ppm detected by the infrared analyzer

VALIDATION:

displays the value of last validation against the last stored calibration value (in percentage %).

REAGENT TANKS LEVEL:

allows to reset the counter to 100%. This operation should be done when the reagent container is refilled.

In order to reset the counter simply press the reagent tank. A new button will appear: PRESS 3 sec TO FILL REAGENTS Pressing the button, the counter will be reset to 100%.

4.3 CALIBRATION PAGE

Service password Press

7010 TOC ANALYZER - USER MANUAL

In the right side the current calibration parameters stored in the analyser are displayed only.

ppm zerogas:

expressed in ppm generated by carrier gas (ambient air filtered by sodalime filter) as detected by the infrared analyzer

ppm liq. zero:

ppm generated by reagents and distilled water as detected by the infrared analyzer

ppm baseline

mg/l standard:

solution used for calibration

ppm span gas:

ppm generated by the standard solution as detected by the infrared analyzer

the residual CO2 concentration value

the CO2 concentration value expressed in

= ppm zerogas + ppm liq. zero

displays the value in mg/l of the standard

the CO2 concentration value expressed in

to go back to MAIN PAGE Press

4.3.1 ZEROGAS

To exit Zerogas simply press

Starts a zerogas cycle. This value is typically lower than 200 ppm

The

ZEROGAS

stored in the analyzer database.

ZEROGAS

programmed in the timing menu or by manually pressing for few seconds the button

During a zerogas cycle the pumps and UV lamps are switched off. In these conditions the carrier gas goes through all the fluidics to reach the detected by the infrared analyzer decreases so that after the programmed delay time it will be stable and equal to the generated by carrier gas only. This value is stored and shown as

ZEROGAS

NDIR

value expressed as

cycle starts automatically at the time and interval

ZEROGAS

. The

CO2

on the calibration page.

concentration value expressed in ppm

CO2

ppm is automatically

CO2

7010 TOC ANALYZER - USER MANUAL

A graphic of the trend of the ppm of

NDIR

programmed for the zerogas cycle, the value of ppm of measured and the last zerogas value.

Refreshing frequently this value is extremely important because the sodalime loses its capacity to adsorb

If the high” will be activated and the analyzer will display this alarm message.

is shown together with a counter of the seconds

ZEROGAS

exceed a certain preset limit, the alarm “Zero too

CO2

value detected by the

CO2

from ambient air.

CO2

4.3.2 LIQUID ZERO

7010 TOC ANALYZER - USER MANUAL

Allows to store the zero procedure, perfo rmed with distilled water.

This calibration should be made manually every time the reagents are replaced and every time it is intended to perform a manual calibration.

The

LIQUID ZERO

inlet tubing of the sample pump from the external fast-loop reservoir and connecting it to a distilled water container, using an extension tube if necessary.

With these conditions the distilled water is pumped through all the fluidics until the operator decides that the concentration value expressed in ppm detected by the infrared analyzer is stable.

cycle is performed manually taking out the

CO2

value of liquid zero calibration

CO2

Press stable reading then press the seconds. The page closes and the ppm of infrared analyzer is then stored in the instrument.

LIQUID ZERO

button. Wait for at least 30 minutes for a

PRESS TO CAL

CO2

button for few

detected by the

4.3.3 MANUAL CALIBRATION

7010 TOC ANALYZER - USER MANUAL

Allows for storing the span calibration procedure , performed with a standard solution.

Suggested standard solution value to be used for calibration should be equal to at least 50% of analyzer full scale.

The

CALIBRATION

inlet tubing of the sample pump from the external fast loop reservoir and connecting it to the selected standard solution container, using an extension tube if necessary.

Press it possible to set the value in mg/l of the standard solution used for calibration .

With these conditions the standard solution is pumped through all the fluidics. Once the operator decides that the concentration value expressed in ppm as detected by the infrared analyzer and the Value expressed in mg/l is stable, press the the last stored baseline value is subtracted and the ppm span gas value is stored.

MANUAL CAL

PRESS TO CAL

cycle is performed manually taking out the

button by pressing the standard number is

button for few seconds. The page closes,

CO2

value from the liquid span

CO2

If the infrared analyzer during the manual calibration is out of the tolerance range, the a nalyzer will abort the calibration showing an error message “Calibration error” in the main page.

CO2

concentration value expressed in ppm detected by the

4.3.4 RUN AUTOCAL

Allows to run an autocalibration cycle.

The standard value to be used should be the one displayed in Manual Cal.

AUTOCAL

programmed on timing menu if autocalibration is enabled as auto mati c option.

If autocalibration is the selected automatic option, at the time programmed on timing menu the calibration pump

With these conditions the standard solution is pumped from a container placed beneath the analyzer through all the fluidics for the number of minutes programmed on timing menu.

cycle starts automatically at the time and interval

(11 )

is switched on.

7010 TOC ANALYZER - USER MANUAL

The

CO2

concentration value expressed in ppm detected by the

infrared analyzer will increases until after the programmed delay time when it will be stable and equal to the standard solution.

After subtracting the last stored baseline value, it will stored and shown as ppm span gas.

The trend of analysis values is displayed during autocalibration cycle together with ppm of and carrier flow.

CO2

measured by

CO2

generated by the applied

NDIR

, last calibration stored

To exit RUN AUTOCAL press

4.4 TIMING PAGE

Service password Press

7010 TOC ANALYZER - USER MANUAL

ZeroGas time

Using the sliding switch it is possible to enable automatic zero gas. Zerogas hours: allows to set the time for automatic zero calibration (hour, minutes) of the infrared analyzer Zerogas days of the week: allows to set the zero automatic calibratio n interval of the infrared analyzer simply by selecting one or more days of the week

Extra Relay

Using the switch it is possible to enable It is possible also to set the frequency (min) and the running time (sec). When ON a 24 Vdc will be available on the terminal of the user connections.

COND delay min

Allows to set the number of minutes that analyzer reconditions with sample before on-line operation after an autocal/val/clean or when switched on after a standby or a stop. ZGas period sec Allows to set the number of seconds that zerogas cycle is active before storing the CO2 ppm value corresponding to zerogas. Clean (autocal / autoval / autoclean) delay min Allows to set the number of minutes that the auto pump is swit ched on during an autocalibration / autovalidation / autocleaning cycle

(ON)

or disable

(OFF) Extra Relay

(OFF)

to go to MAIN PAGE Press

AUTO time

Using the switch it is possible to enable function AUTO hour : allows to set the time (hour, minutes) of automatic function AUTO days of the week: allows to set the enabled automatic option interval of the analyzer simply by selecting one or more day of the week

(ON)

or disable

(OFF)

automatic

7010 TOC ANALYZER - USER MANUAL

4.5 GENERAL SETUP PAGE

Admin password Press

DATE :

press current date to set the date

(day, month, year

)

ALARMS

FLOW MIN

If the value of the carrier gas flow decreases b elow this value, the carrier flow alarm switches on.

ZEROGAS MAX

to the zero gas. If exceeded it switches on the zerogas alarm.

VAL TOLERANCE ALARM mg/l

value alarm contact (in mg/l)

: allows to set the alarm of the carrier gas flow.

.: allows to set the maximum value of CO2 corresponding

: allows to set a tolerance acceptable for validation.

: allows to set the value that if exceeded switches on the

GENERAL SETTINGS

Analyzer mg/l CO2 ppm

installed. There are three options: 1000, 5000 and 10000 ppm.

Range Factor

: allows setting of the range of the analogue output : factor to be applied if dilution is used and/or as a con version

factor to report results as another parameter i.e. COD.

: allows setting of the range in mg/l of the analyzer

: allows setting of the range in ppm of the IR detector

OUTPUTS

Relay A

(ONLINE, OFFLINE , LOSS OF SAMPLE, RESULT ALARM, VALID ALARM, REAG ALARM, CALIB ERROR)

Relay B

4-20 mA TES T: allows to test the 4-20 mA output Using the switch it is possible to enable the 4-20 mA output. Set the percentage of the scale and connect a multimeter to the analogic output terminal of the user connections.

0% corresponds to 4 mA 50% corresponds to 12 mA 100% corresponds to 20 mA

: allows to set the function of the relay A

: FAULT (only read window)

(ON)

or disable

(OFF)

the test of

to go to MAIN PAGE Press

TIME :

press current time to set the time

(in hours/minutes 24 hours format)

MANUAL CALIBRATION SETTING

ZEROGAS ppm ZEROLIQ ppm SPAN VALUE ppm

: allows to set manually zerogas value in ppm of CO2

: allows to set manually zero liquid value in ppm of CO2

: allows to set manually span value in ppm of CO2

4.6 DATA LOGGER PAGE

Service password Press

7010 TOC ANALYZER - USER MANUAL

The Result Notepad that is accessible from the Main screen shows results for the current day. Records for a longer time are stored on the instrument and can down loaded onto a USB stick.

Here results are recorded every 15 min for up to 30 calendar days. Once 30 days data has been collected then the files are overwritten on a FIFO basis.

To download result s stored in the data logger you first need to insert a USB key.

Open the door of the electronic enclosure and insert a USB key into the port that is positioned on the cover behind the door.

Go to the data logger menu (violet USB logo) and press on the

button, keeping it pressed until the software automatically

exits back to the main screen. On the USB key there will now be a

to go to MAIN PAGE Press

folder named ‘datalog’, inside which there is another folder named ‘’TOC’’, where you will find one csv file for each day's data.

Additional buttons are available on t he data logger screen.

CLEAR FIRST DAY

logger memory.

CLEAR ALL

DTLG ON/OFF

ALARM LOG

– deletes all data in the data logger memory.

- Alarm Log - It allows to access to the Alarm log

– deletes the earliest day's data in the data

– switches on and off the data logger.

page.

4.7 ALARM LOG PAGE

Service password Press Press

TIME

- Alarm occurring time

7010 TOC ANALYZER - USER MANUAL

to go to MAIN PAGE Press

EVENT

RESET TIME

- kind ofalarm

- time when the alarm resets

4.7 DUAL STREAM CONFIGURATION - OPTION

If the analyzer is configured as a dual channel instrument, the extra relay is used to control an external valve.

On the Main page the current results for streams A and B are displayed.

On the Timing page the user is able to select the length of time each stream will be measured. A conditioning period as set in the Timings page will take place between each change of stream.

On the Settings page there is the possibility to set two different full scale values for the two analogue outputs. In addition two independent Factor settings for each stream can be entered for correct calculation according to the dilution used or as a conversion factor to report results as another parameter i.e. COD. Similarly two independent Alarm settings can be entered.

7010 TOC ANALYZER - USER MANUAL

4.8 DUAL RANGE OPTION

It the analyser is confi gured as dual range instrument, the extra relay is used to control an external dilutor.

When the result exceeds the programmed threshold the analyser will switch from range L (low) to range H (high) and the extra rel ay will be activated.

Every time the analyzer is turned ONLINE or after an OFF LINE

7010 TOC ANALYZER - USER MANUAL

operation ( ZERO GAS, AUTOFUNCTION, LOSS OF SAMPLE) , it starts from the high range condition (diluted sample).

A conditioning period will divide the two statuses during which no results will be displayed.

After t he conditioning period the result according to range H (high) is shown

7010 TOC ANALYZER - USER MANUAL

When the DUAL RANGE option is selected, the TIMING PAGE allows to set the thresholds where the instrument will switch between high and low ranges.

Only the analog output referring to the current range is active while the other is forced down to 0 (4 mA).

External dilu ti on factor determines the range H (high) result calculation

The A relay can be used to report the range L (low) or H (high) status.

7010 TOC ANALYZER - USER MANUAL

MAINTENANCE

7010 TOC ANALYZER - USER MANUAL

Regular maintenance will ensure excellent analyzer performance over a number of years. It is important to follow a scheduled maintenance program to make certain the analyzer is kept clean and in good condition.

OPERATION FREQUENCY

daily weekly monthly 4 monthly annual

Visual check of FAULT alarms

Visual check of Liquids Enclosure

Visual check of halogens filter

Visually inspect the scrubber and UV scrubber for normal bubble flow

Sample fast loop reservoir cleaning* Refill reagent containers Scrubber and gas liquid separator cleaning* Soda lime replacement in soda lime filter** Copper wool replacement in halogens filter* Pumps tubing replacement* UV lamps check for leakages and tubing connection replacement Maintenance visit by qualified service engineer

* Frequency of cleaning/replacement dependant on sample quality ** Frequency of replacement dependant on ambient air quality

7010 TOC ANALYZER - USER MANUAL

5.1 PUMP TUBING REPLACEMENT

The peristalt ic pump heads are located in the Liquids Enclosure. Before proceeding to replace the tubing, please read carefully Section 1 of this manual on hazards and dangers. It is recommended to wear appropriate clot hing, gloves and eyes protection. Phosphoric acid, sodium persulfate and cleaning solut ions should be handled with extreme care. Proceed as follows:

With the analyzer in normal online operation, disconnect all solution and sample lines from their containers and reconnect them to a distilled water source. Leave the analyzer running in this way for at least an hour.

Put the analyzer in Standby. Pumps and UV lamps will be switched off.

Using the key, open the Liquids Enclosure.

Disconnect each pump tubing from their inlet and outlet fittings, taking care to note which

fitting will be needed to reconnect to which pump.

Undo the four wings nuts on the mounting screws that supports pump heads.

Slide the pump heads to left and remove them from the mounting screws.

Carefully separate the two halves, avoiding dropping the rotor and then removing the

used tubing.

Place the pump half containing the rotor in one hand and move the rollers in the 2, 6 and 10 o’ clock positions. Place tubing in the outer port and against the two rollers as shown, keeping your thumb on the tubing to hold it in place. Insert the tubing loading key on the back of the rotor shaft and push the rotor in as far as possi ble. The tubing should now be positioned deep into the pump head body. Wit h the key firmly pressed against the rotor, turn counter-clockwise, while pushing down until tubing is fully in place around the rotor.

With the tubing is now on place, remove the key and position the other pump half onto the rotor shaft

and snap shut, being careful not to pinch the tubing between the plastic pump halves.

Check if the pump turns correctly using the key.

Holding the two parts of the pump head tightly together, slide it into the mounting screws moving the

rotor block with the key or with a screwdriver until the shaft aligns with the motor drive.

Replace the four wing nuts, tightening them to finger tight so to have a firm mounting of the pump

head.

Repeat the steps fromDtoLfor each additional pump head for which it is necessary to replace the

tubing.

Reconnect the acid and persulfate intake tubing to their containers, run online t he analyser.

7010 TOC ANALYZER - USER MANUAL

The analyser will start the conditioning cycle, with status indicator flashing with green light, until the conditioning t ime will be expired. After the conditioning time of 30 minutes, the analyser will start regular on line measurements.

5.2 COPPER WOOL REPLACEMENT

The halogens filter is located into the electrical enclosure ( please read the hazards and dangers list in section 1). This operation should be made by qualified personnel who have been fully trained and has professional experience to avoid electricity hazards and dangers.

put the analyser in stand-by and open the analyzer electrical enclosure

disconnect the inlet and outlet tubing of the filter from their fittings

remove the filter plastic body from its support clamp

7010 TOC ANALYZER - USER MANUAL

unscrew top and bottom caps from filter body

with extreme care, using a proper tool, pull out the used wool from ther plastic cylinder

replace the used wool with new wool and press it into place to form a compact pod.

screw back on the top and bottom caps

put the filter in the clamp, connect fittings and turn on line the analyzer

5.3 SODALIME REPLACEMENT

The sodalime filter is located inside the electrical enclosure (refer section 1 for hazard warnings). All handling and manipulations operations on chemicals labelled with 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 prof essional experience to avoid chemical hazards and dangers.

Warning: Sodalime (granules) is a strong oxidizer and should be handled with extreme care.

Irritating to eyes, respiratory system and skin. It causes burns. Avoid contact with skin. Do not breathe dust. Wear suitable gloves, face mask, clothes protection and

operate in an adequate environment. Before to proceed to sodalime replacement in sodalime filter,

read with care the material safety data sheets supplied with this chemical to take all the necessary precautions when handling.

7010 TOC ANALYZER - USER MANUAL

put the analyser in stand-by and open the analyzer’s electrical enclosure

disconnect the inlet and outlet tubing of the filter from their fittings

remove the filter plastic

body from its support clamp

unscrew filter upper cap, pull out the wool disc and pour the used sodalime into a proper container for disposal, taking all precautions its handling

fill the plastic body with new sodalime granules, insert the wool disc and screw the upper cap

install the filter on its support clamp and reconnect inlet and outlet tubings, put the analyser on line

Used sodalime must be disposed according with national or local environment al regulations regarding hazardous and poisonous materials.

5.4 UVR TUBING'S CONNECTION REPLACEMENT

WARNING – UV lamps may be hot if recently powered. Handle with suitable gloves.

Put the analyzer in standby mode

Open the analyzer Liquid Enclosure

Dismount the UV lamps from their supports

Cut the plastic clamp and the norprene tubing's connection and replace

them with new ones

The Teflon tubing should be inserted inside the quartz inlets/outlets of the UV lamps, taking care not to impede the liquid flow (see adjacent diagram)

The norprene tubing should cover the Teflon tubing and the arm of the quartz inlets/outlets of the UV lamps

7010 TOC ANALYZER - USER MANUAL

Use the black clamps supplied to fix the norprene tubing to the Teflon

tubing

Check the clamp has been correctly positioned (that there are no leakages) using a syringe with DI water connected at the same point used to drain the lamps.

If no leakages are found, then remount the UV lamps on their supports

and switch on the analyzer

Once the analyzer has been running for two hours check again for leaks

at the connection to the UV lamps.

5.5 UV LAMP REPLACEMENT

The UV lamps are located in the Liquids Enclosure.

WARNING – UV lamps may be hot if recently powered. Handle with suitable gloves.

Put the analyzer in Standby. Switch off the power.

Using the key, open the Liquids Enclosure. Using a syringe remove the remaining liquid from the UV lamps (see adjacent figure). Reconnect the tubing to the ‘T’ afterwards.

7010 TOC ANALYZER - USER MANUAL

Remove the wires from the cable guide in the top of the Liquid

Enclosure.

Disconnect the UV lamp wires from the rear of the UV lamp power supplies, after first cutting the g ain protecting the connection.

Remove the four screws supporting the lamps using a 3 mm Allen key or driver.

Cut the black clamp holding the tubing to the top and bottom of the lamps.

Connect the replacement lamps to the UV lamp power supply. First slip the supplied thermo–retractable gain over the end of the UV lamp wire. Reconnect the wires with the UV lamp power supply and position the gains over t he connections. Apply heat to contract the gain. The gain is required to protect the connection from humidi ty.

Reinsert the wires into the cable guide.

Reconnect the tubing to the top and bottom of the UV lamps following the instructions in Section 5.4.

5.6 FUSES REPLACEMENT

The fuses are located inside the analyzer electrical enclosure (refer to section 1 for hazards and dangers warnings) .

All operations within the electrical enclosure should be made by qualified personnel in accordance with national or local codes and regulations.

Qualified Personnel means a person who has been fully trained and has professional experien ce to avoid electricity hazards and dangers.

The

701 0 TOC

labelled as F1 and F2. Before to proceed to service operations on the electrical enclosure, read carefully all the information written in this manual regarding this matter.

analyzer h as two fuses located inside the USER CONNECTIONS

7010 TOC ANALYZER - USER MANUAL

To avoid any risk, turn off the analyzer main power before servicing the electrical enclosure.

turn off main power

open the electrical enclosure

remove the protection cover

remove the small protection cover of the fuse assembly

remove the fuse

check the fuse and if broken replace it with a new one.

6 PREPARATION OF THE CHEMICALS

7010 TOC ANALYZER - USER MANUAL

The chemica l solutions used with online standard operation are :

phosphoric acid, 10% solution v/v and sodium persulfate solu ti on, 1M as reagents

standard soluti on, used in different concent rat ion depending on analyser range to calibrate or validate the TOC

cleaning solution

optional reducing reagent solution for applications with high content of chlorides

Before to proceed to these solutions preparation, read the material safety data sheets supplied with each chemical to take all the necessary precautions when handling. Chemicals must be handled by qualified personnel trained on hazards and dangers to avoid accidents.

701 0 TOC

analyser in

Metrohm Applikon

TOC operation as solutions or predosed packs.

supplies all the chemicals used for

7010 TOC ANALYZER - USER MANUAL

6.1 PREPARATION OF TOC STANDARD SOLUTION

Use distilled water reagent grade for preparation of TOC standa rd solutions and for analyser zero calibration.

Organic compounds usually used as TOC standards are potassium hydrogen phthalate (KHP) reagent grade and ethylene glycol reagent grade.

The table 4.1 is shows a list of other calibration solution compounds that have been approved for this use.

Before to proceed to prepare the chosen solution, read with attention its material safety data and use all precautions recommended when handling.

Always use suitable wears, gloves, and eyes protection.

For use of powdered chemicals, wear a protective face mask or suitable respirator.

For standard solution preparation, prepare a stock solution by adding the quantity shown in table 4.1 (according to chosen compound and concentration in grams or ml) into a 1000 ml class A volumetric flask.

Dilute to volume with reagent water. If other concentrations are required, dilute accordingly or measure an appropriate ratio of chemical.

Tab. 4-1: Amount (g or ml) for preparation of 1 liter TOC standard solution 1000 mg/l

Organic compound Amount

Ethylene glyco l 2,33 ml Potassium hydrog en phthalate (KHP) 2,12 g Acetic acid 2,50 g Sucrose 2,38 g

7010 TOC ANALYZER - USER MANUAL

6.2 PREPARATION OF COD STANDARD SOLUTION

Use distilled water reagent grade for preparation of COD standard solutions and for analyzer zero calibration.

Before to proceed to prepare the solution, verify eventual toxicity of used chemical and read with attention its material safety dat a and use all precautions when handling.

Always use suitable wears, gloves, and eyes protection.

For use of powdered chemicals, wear a protective face mask or suitable respirator.

For 1000 mg/l standard solution preparation, prepare a stock solution by adding 0,85 g of potassium hydrogen phthalate (K HP ) into a 1000 ml class A volumetric flask.

Dilute to volume w it h reagent water. If other concentrations are required, dilute accordingly or take an appropriate ratio of KHP.

7010 TOC ANALYZER - USER MANUAL

6.3 PREPARATION OF PERSULPHATE SOLUTION

Sodium persulphate is a strong oxidizer and should be handled with ext reme care. Contact with combustible material may cause fire. Irritating to eyes, respiratory system and skin.

May cause sensitizat ion by inhalation and skin contact. Do not breat he dust. Avoid contact with skin. Wear suitable gloves, face mask, protective clothing and operate in an adequate environment. Before to proceed to prepare the sodium persulfate solution, read with attention its material safety data sheet

and use all precautions recommended when handling.

Add 5 liters of distilled water in a 10 liters container that has been previously cleaned and flushed with distilled water.

Add 2380 g. sodium persulfate and dilute to 10 liter volume with distilled water, dissolving the powder by shaking.

Plug the container and shake until all the persulfate is dissolved. Wait for at least half an hour when the solution will appear clear .

Consumption: 1 0 L/month for continuous operation

7010 TOC ANALYZER - USER MANUAL

6.4 PREPARATION OF ACID SOLUTION

Phosphoric acid is a corrosive material and should be handled with extreme care.

It can cause blindness and burns to the skin.

Always wear chemical eye and clothes protection when handling.

Before to proceed to prepare the phosphoric acid solution, read with attention its material safety data sheet and use all precautions recommended when handling.

IMPORTANT WARNING: always add acid to water and never the reverse.

Take care for spills or skin contacts.

Add 8 liters of distilled water in a 10 liters container that has been previously cleaned and flushed with distilled water.

Add very slowly and with extreme care 1175 ml. of 85% phosphoric acid and dilute to 10 lit er volume with distilled water to have a 10% solution.

Plug the container and shake with care the solution.

Note: when the quantity ofTIC in the sample is high it is suggested to use a 20% phosphoric acid solution.

Consumption: 1 0 L/month for continuous operation

7010 TOC ANALYZER - USER MANUAL

6.5 PREPARATION OF REDUCING SOLUTION

Before to proceed to prepare the reducing solution, read with at te nt ion its material safety data sheet and use all

precautions recommended when handling.

Add 8 liters of distilled water in a 10 liter container that has been previously cleaned and flushed with distilled water.

Add 200 g hydroxylamine hydrochloride and dilute to 10 liter volume with distilled water.

Cap the container and dissolve the powder by agitating the container until the solution appears clear.

Consumption: 1 0 L/month for continuous operation

7010 TOC ANALYZER - USER MANUAL

6.6 PREPARATION OF CLEANING SOLUTION

The most suitable cleaning solution depends on the specific analyser application due to chemical and physical characteristics of the analyzed sample and the chemical compatibility of analyzer materials.

Unless a suitable cleaning solution ia al ready in use for the specific application, it is recommended to use

Applikon Cleaning Solution

To establish a good cleaning solution choice, it is recommended to observe to different analyser parts involved in sample flow and note the points of fluidics that become more and more dirty.

Try to establish the best interval and duration of cleaning cycle to optimize the dirt removal from these points.

If necessary, contact the

Always wear eyes, gloves and clothes protection when handling.

Before to proceed to prepare cleaning solution, read with attention its material safety data sheet and use all precautions recommended when handling.

The Cleaning solution should not be used if the hardness of the water is high, because calcium will precipitate!.

Add 10 g of sodium hydroxide and dilute to 1 liter. Plug the container and shake to dissolve.

Add 2 g of dichloroisocyanuric acid, sodium salt 96%. Plug the container and shake with care to dissolve.

Metrohm Applikon

service department to have advice on this matter.

Metrohm

7010 TOC ANALYZER - USER MANUAL

6.7 PREPARATION OF TC REAGENT SOLUTION

Sodium persulphate is a strong oxidizer and should be handled with extreme care. Contact with combustible material may cause fire. Irritating to eyes, respiratory system and skin.

May cause sensitization by inhalation and skin contact. Do not breathe dust. Avoid contact with skin.

Phosphoric acid is a corrosive material and should be handled with extreme care. It can cause blindness and burns to the ski n. Always wear chemical eye and clothes protection when handling. Avoid contact with skin.

IMPORTANT WARNING: always add acid to water and never the reverse.

Wear suitable gloves, face mask, protective clothing and operate in an adequate environment.

Before to proceed to prepare the mixed solution, read with attention the material safety da ta sheet and use all precautions recommended when handling.

Add 7 liters of distilled water in a 10 liters container that has been previously cleaned and flushed with distilled water. Add very slowly and wit h extreme care 1175 ml. of 85% phosphoric acid and dilute to 10 liter volume with distilled water to have a 10%

solution. Plug the container and shake with care to fully mix the acid with the water. Add 2380 g. sodium persulfate, dissolving t he powder by shaking. Plug the container and shake until all the persulfate is dissolved. Wait for at least half an hour when the solution will appear clear . Consumption: 10 L/month for continuous operation

7.0 ANALYZER SHUT DOWN

7010 TOC ANALYZER - USER MANUAL

For a short stop (from 1 hour to 3 days) it is preferable if possible that the operation. The lamps should not be lit without liquid flowing through them and frequent switching on and off of the power should be avoided.

In this case it is recommended to disconnect all solution and sample lines from their containers and reconnect them to a distilled wat er source, leaving the analyzer running.

For longer shutdown period, proceed as follows:

Disconnect all solution and sample lines from their containers and reconnect them to a distilled water source, leaving

the analyzer running.

Run the analyzer for at least 1 hour in these conditions.

After 1 hour, put the analyzer on Standby

Remove power from the analyzer by disconnecting the plug from the power line.

Dispose of remaining reagent solutions and standards according to local regulations.

If the analyzer is to moved or shipped to a new location then all liquid should be removed beforehand.

Proceed as above to rinse the analyzer with distilled water.

After 1 hour remove the tubing from the distilled water and run the analyzer for a further 30 min.

Put the analyzer in Standby. Switch off the power.

Remove the remaining liquid from the U-tube by taking off the cap on the right arm and sucking out the liquid with a

suitable syringe and tubing.

Using a syringe remove the remaining liquid from the UV lamps. Reconnect the tubing to the ‘T’ afterwards.

701 0 TOC

analyzer remains in continuous

PROBLEM PROBABLE CAUSE CHECK TO DO CORRECTIVE ACTION

FAULT ALARM

loss of sample

low flow / reactor carrier gas

span calibration/ validation fa iled

zero gas calibration failed

Check sample presence in the fast-loop reservoir

Check carrier gas flow value in cc/min

Repeat calibrat ion / validation.

Repeat zero calibration and check the ppm CO2 value

restore sample flow

check carrier gas line coming from air compressor tubing looking for blockages and/or eventual fail ures

check for pump delivery of standard solution and persulfate; prepare a fresh standard solution and make a double check on its correct value; verify that the infrared analyser is properly working

replace sodalime in sodalime filter, check the gas lin e is free from obstructions f rom condenser to NDIR. verify that the infrared analyser is properly working

(09)

until UV reactor outlet

loss of reagents

check reagent tanks level check reagent days counter

Check reagents level in their containers Reset reagent counter

7010 TOC ANALYZER TECHNICAL DATA

Analysis: TOC Method: Total Organic Carbon (TOC) measurement with TIC removal by acidification and sparging,

sodium persulfate UV promoted oxidation,

CO2 detection by non dispersive infrared analyser (NDIR) Ranges: from 0-5 a 0-20000 mg/l (with dilution)// Others upon request Response time: approximately from 5 minutes, depending on range Lower detectable limit: 0,2 mg/l Accuracy: +/- 2% of full scale Repeatibility: +/- 2% of full scale Drift: less of 2% with autovalidation Autocalibration, Autocleaning, Autovalidation Selectable ( specific pump head)

POWER REQUIREMENTS:

Power supply: 115VAC - 230VAC, 50/60 Hz Power consumption: MAX 350 VA for 115 Vac / MAX 250VA for 230Vac Fuses: 3,15 A (230V) / 4A (115V)

INSTALLATION REQUIREMENTS:

Mounting: wall or support rack Environmental temperature: 5-40°C (41-104 °F) Humidity: 0-75% Cabinet: cold rolled epoxy powder coated steel Dimensions: 750 x 600 x220 mm Weight: Kg. 37 ( approximately depending on range configuration) Reagents consumption: 10 liters / 28 days Analog outputs: N°2 4-20 mA ,optically isolated, for measurement data

Alarms: 2 SPDT contacts. Relay A is a programmable: online, offline, loss of sample, result alarm,

validation alarm, reagent alarm, calibration alarm. Relay B is a fault alarm

SAMPLE REQUIREMENTS:

Inlet pressure : atmospheric Outlet pressure: atmospheric Flowrate: 100-500 ml/ min (fast loop reservoir) Sample connection tubing: fast-loop reservoir fitting with flexible tubing 6 ext mm.

TOTAL CARBON (TC) FLOW DIAGRAM

7010 TOC ANALYZER - USER MANUAL

CLEANING TC REAGENT

SODIUM PERSULFATE CLEANING ACID SAMPLE

TOC FLOW DIAGRAM USING NITROGEN AS CARRIER GAS

7010 TOC ANALYZER - USER MANUAL

Metrohm

Applikon BV

DE BRAUWEG 13

3125 AE SCHIEDAM

THE NETHERLANDS

7010 TOC ANALYZER - USER MANUAL

E-mail : info@metrohm-applikon.com

Tel. +31 (0)10 2983555 Fax +31 (0)10 4379648

Metrohm 7010 TOC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual