Mettler Toledo Thornton 5000TOC Operating Procedures Manual
Part No. 84468
5000TOC Sensor
Standard Operating Procedure
for
• TOC Calibration
• Conductivity Calibration
• Temperature Calibration
• Flow Rate Calibration
This document contains proprietary information, which is protected by copyright. All rights are reserved. No part of this
document may be photocopied (other than where specifically noted), reproduced or translated, into another language without
the prior written consent of Mettler-Toledo Thornton, Inc.
©Mettler-Toledo Thornton, Inc. 2007
No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying (other than where specifically noted), for any purpose without the express written
permission of Mettler-Toledo, Inc.
U.S. Government Restricted Rights: This documentation is furnished with Restricted Rights.
METTLER TOLEDO THORNTON RESERVES THE RIGHT TO MAKE REFINEMENTS OR
CHANGES WITHOUT NOTICE.
IMPORTANT SAFETY INFORMATION
Please read thoroughly before operating the 5000TOC System Suitability Test Kit -
• Follow all warnings, cautions, and instructions indicated on and supplied with this product.
• Install equipment as specified in this instruction manual. Follow appropriate local and national codes.
• Use only factory documented components for repair. Tampering or unauthorized substitution of parts and procedures can
affect the performance and cause unsafe operation of your process as well as void factory warranties.
• Protective covers must be in place unless qualified personnel are performing maintenance.
• If this equipment is used in a manner not specified by the manufacturer, the protection provided by it against hazards may
be impaired.
• Prior to shipping the sensor back to the factory for repair or re-calibration, water MUST be drained from sensor to avoid
damage due to freezing.
WARNINGS:
• Installation of cable connections and servicing of this product require access to shock hazard voltage levels.
• Main power must employ a switch or circuit breaker as the disconnecting device for the equipment.
• Electrical installation must be in accordance with the National Electrical Code and/or any other applicable national or local
codes.
• Safety and performance require that this instrument be connected and properly grounded through a three-wire power
source.
This manual includes safety information with the following designations and formats:
WARNING: POTENTIAL FOR PERSONAL INJURY.
CAUTION: possible instrument damage or malfunction.
NOTE: important operating information.
Definition of Equipment Symbols
On the instrument indicates: Warning Caution, risk of electric shock.
On the instrument indicates: Caution (refer to accompanying documents).
~ On the instrument indicates: There is alternating current present.
TABLE OF CONTENTS
1. INTRODUCTION ....................................................................................................................1
2. SCOPE ................................................................................................................................1
3. CALIBRATION SELECTION AND SEQUENCE ............................................................................. 1
4. EQUIPMENT REQUIRED .........................................................................................................1
5. EQUIPMENT DATA ................................................................................................................ 1
6. FLOW RATE CALIBRATION ..................................................................................................... 2
6.1. Flow Rate Verification Before Calibration................................................................................... 2
6.2. Flow Rate Calibration............................................................................................................. 2
6.3. Flow Rate Verification After Calibration...................................................................................... 3
7. EQUIPMENT PREPARATION ...................................................................................................3
7.1. Installing the Thornton 5000TOC Calibration Test Kit Brackets..................................................... 3
7.2. Installing the Thornton 5000TOC Calibration Kit Tubing..............................................................5
7.3. Final Installation of the Thornton 5000TOC Calibration Kit .......................................................... 7
8. 770MAX CONFIGURATION ....................................................................................................7
9. TEMPERATURE CALIBRATION ................................................................................................8
9.1. T1 Temperature Verification Before Calibration........................................................................... 8
9.2. T1 Temperature Calibration..................................................................................................... 8
9.3. T2 Temperature Verification Before Calibration........................................................................... 9
9.4. T2 Temperature Calibration..................................................................................................... 9
10. CONDUCTIVITY CALIBRATION................................................................................................ 9
10.1. C1 Conductivity Verification Before Calibration ........................................................................ 10
10.2. C1 Conductivity Calibration .................................................................................................. 10
10.3. C2 Conductivity Verification Before Calibration ........................................................................ 11
10.4. C2 Conductivity Calibration .................................................................................................. 11
11. TOC CALIBRATION.............................................................................................................. 12
11.1. TOC As Found..................................................................................................................... 12
11.2. TOC Calibration Procedure.................................................................................................... 13
11.3. TOC Calibration Verification Procedure ...................................................................................13
12. RESTORE TO OPERATION..................................................................................................... 13
13. SETTING SAMPLE FLOW RATE .............................................................................................14
13.1. Flow Rate Adjustment Procedure ...........................................................................................14
13.2. Flow Rate Indication ............................................................................................................15
14. WORKSHEET 1: PART NUMBER AND SERIAL NUMBER DATA ..................................................16
15. WORKSHEETS FOR CALIBRATION AND VERIFICATION............................................................17
1. Introduction
The Thornton 5000TOC Total Organic Carbon Sensor and 770MAX meter measures the amount of organic carbon in high purity
waters by oxidizing organic carbon to CO
compensated conductivity measurements of the sample flow stream at points before and after oxidation is used to calculate the
amount of organic carbon present. The complete calibration of the 5000TOC Sensor consists of calibration of the following.
• flow rate sensor measurement
• two temperature sensor measurements
• two conductivity sensor measurements
• TOC measurement
Throughout the test procedure, the units “ppb” or “ppb Carbon” and “µg Carbon/L” will appear. They are identical for this
procedure. “ppb” (or ppm) is the common terminology used throughout the industry, though it is not a recognized SI unit.
with appropriate UV radiation. The resulting increase between two temperature-
2
2. Scope
This document provides procedures to calibrate the Thornton 5000TOC Total Organic Carbon Sensor (PN 58 036 001 or PN
58 036 002 and related part numbers). The 5000TOC Sensor is used with the Thornton 770MAX meter. Calibration of the
770MAX meter is covered in separate documentation.
3. Calibration Selection and Sequence
Calibration of the 5000TOC Sensor consists of four sequential calibration procedures; flow rate, temperature, conductivity, and
TOC. To perform a complete calibration of every component of the 5000TOC Sensor, these procedures must be performed in
this order. If you choose to calibrate the TOC measurement more frequently than the other measurements, please refer to
Section 11 of this manual.
4. Equipment Required
• Thornton 5000TOC Calibration Test Kit (Thornton PN 58 091 534). This consists of a calibrated conductivity sensor
(230-201), 5 foot patch cable (Thornton PN 1005-79), 316L SS flow housing (Thornton PN 1000-30), holding brackets,
SOP for Calibration, pump, power supply, and miscellaneous connectors and tubing.
• Thornton 5000TOC Calibration Solution Set (Thornton PN 58 091 529).
• Stop watch or other timing device with 1 second resolution.
• 100 mL or larger volumetric container such as graduated cylinder with <3% tolerance.
Note: Alternatively, item 1 can be replaced with a Thornton System Suitability Test Kit (Thornton PN 58 091 525) in conjunction
with a Thornton Calibration Test Accessory Kit (Thornton PN 58 091 528) to execute this procedure.
Note: Use a hold time to freeze the relay and analog outputs so that alarms are not triggered during any service
procedures. Normal relay and analog output operation resumes when the set period has elapsed or when the hold time is
reset to zero. Set hold time by pressing “Menu” from the 770MAX main display. Scroll to “Set Hold time” by using the
up/down arrows. Press “Enter”, then enter a time between 1 to 99 minutes, and press “Menu”. The hold time is now set.
Caution: Be sure to adjust needle valve to less than 3 turns from closed position before re-installing into process line!
5. Equipment Data
Record all relevant data identified in Worksheet 1.
Page 1
6. Flow Rate Calibration
This procedure uses a “volume and time” method for calibrating the flow sensor. Process water is sufficient to use for
this calibration. The end of the drain tube at the sample outlet is the measurement point.
NOTE: Since it is possible for the person performing this calibration to come into contact with the process water, use of
protective gloves, or other suitable safety equipment is recommended.
Caution: If the process water is hot, protection from direct contact should be used, or an alternate source of water must
be provided.
6.1. Flow Rate Verification Before Calibration
1. Adjust the 5000TOC flow rate to 20 ± 1 mL/min as described in Section 13. Setting Sample Flow Rate.
2. Arrange the drain tube at the atmospheric drain such that the water dripping from it may be collected into the
volumetric container.
3. On the 770MAX, press Menu (exit).
4. Press S or T to select Calibrate. Press Enter (or Page Down).
5. Press S or T to select Sensor. Press Enter (or Page Down).
6. Enter Output Hold Time. Press Enter (or Page Down). “Output Hold Time” is the amount of time that you want the
present relay status and analog output value to be held (unchanged) while calibration is performed.
7. Press S or T to select the letter for the measurement of the 5000TOC Sensor being calibrated. Any of the various
sub-sensors within the 5000TOC Sensor may be calibrated from any other measurement letter. For example, if
Measurement C is the TOC from the unit being calibrated, and Measurement D is its conductivity, then any of the subsensors within the unit may be calibrated from either Measurement C or D. Press Enter.
8. Press S or T to select 2-point. Press Enter or X.
9. Press S or T to select the Flow. Press Page Down. The 770MAX should now be displaying the 5000TOC Sensor
flow rate.
10. Place a dry volumetric container under the drain line to capture the water, and begin the time measurement using the
stop watch. It is important that the water collection and time start be closely matched.
11. Collect a known volume of water with the volumetric container for a specific time, at least 3 minutes.
12. Record in Table 1 Section A the volume of water in mL and the elapsed time in seconds. These two values determine
the reference flow rate.
13. Calculate the reference flow rate and record as F
may also be determined by weight. Measure the mass increase of the container in grams, and divide the mass by the
density of the water (typically, 1.00 g/mL at room temperature).
in Table 1 Section A according to the equation below. The volume
ref
14. Record the flow rate as shown on the display of the 770MAX as the F
15. Subtract the measured flow rate from the reference flow rate (F
16. If the absolute value of the difference is less than the limit, then flow rate adjustment is not required. Press Menu to
exit and proceed to Section 7. Equipment Preparation. Otherwise, leave the 770MAX in its current state and proceed to
the next section.
6.2. Flow Rate Calibration
NOTE: All flow adjustments are to be made using the needle valve on the inlet of the 5000TOC Sensor..
1. Using the display on the 770MAX (in the calibration mode as described in Section 6.1), adjust the flow rate through
the 5000TOC Sensor to about 24 ± 1 mL/min as indicated on the 770MAX display.
2. Place a dry volumetric container under the drain line to capture the water, and begin the time measurement using the
stop watch. It is important that the water collection and time start be closely matched.
Page 2
==
F(mL/min)RateFlow
ref
×
(sec)TimeElapsed
– F
ref
before
(mL)collectedvolumesec/min60
eq 1
value in Table 1 Section A.
before
).
3. Collect a known volume of water with the volumetric container for a specific time, at least 3 minutes.
4. Record in Table 1 Section B the volume of water in mL and the elapsed time in seconds.
5. Using eq 1, calculate the water flow rate and record as F
in Table 1 Section B.
ref1
6. Enter the reference flow rate into the 770MAX and press Page-Down.
7. Wait while the calibration is being performed.
8. Adjust the flow rate to about 16 ± 1 mL/min.
9. Empty the volumetric container. Repeat steps 2-7.
10. Record data as F
in Table 1 Section B.
ref2
11. After the flow sensor calibration is completed, enter the correct date. Press Page-Down.
12. Select YES to save the new calibration data within the 5000TOC Sensor.
Note: if NO is selected, the data will only be temporarily saved, and will revert back to the previous value should power be lost
or the 5000TOC Sensor patch cable is unplugged.
6.3. Flow Rate Verification After Calibration
1. Repeat steps 1-11 in Section 6.1. to verify the flow sensor is in calibration.
2. Record the volume of water in mL and the elapsed time in seconds in Table 1 Section C. These two values determine the
reference flow rate.
3. Using eq1, calculate the reference flow rate and record in Table 1 Section C as F
4. Record the flow rate as shown on the display of the 770MAX as F
5. Subtract reference flow rate from the after flow rate (F
ref
– F
after
).
in Table 1 Section C.
after
.
ref
6. If the absolute value of the difference is less than the limit, then flow rate calibration is complete. Otherwise, return to Section
6.2..
Flow Calibration is complete.
7. Equipment Preparation
7.1. Installing the Thornton 5000TOC Calibration Test Kit Brackets
The Thornton 5000TOC Calibration Test Kit provides an easy means to introduce calibration solutions into the 5000TOC Sensor.
This kit is also used for Temperature, Conductivity and TOC calibrations. Components in this kit include a bracket assembly,
transfer cap assembly, assorted fittings, 30 cc plastic syringe, positive displacement pump and universal AC power supply.
1. Remove the Main Bracket A from the Calibration Kit and install on top of the 5000TOC Sensor as illustrated in Figure 1.
2. Remove the Ref. Sensor Holder from the Calibration Kit and install it on the above assembly as illustrated in Figure 1.
3. Remove the Main Bracket B from the Calibration Kit and install as illustrated in Figure 1.
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