Rosemount 2100A Process Total Organic Carbon TOC Analyzer-Rev E Manuals & Guides

Rosemount Analytical

M

ODEL

P

ROCESS TOTAL ORGANIC CARBON

A

NALYZER

I

NSTRUCTION MANUAL

2100A

748263-E

OTICE

N

The information contained in this document is subject to change without notice.

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Manual Part Number 748263-E
March 2001
Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

C

ONTENTS

PREFACE .................................................................... P1

SAFETY SUMMARY ..........................................................................................P1

SPECIFICATIONS - OPERATIONAL.................................................................P4

SPECIFICATIONS - PERFORMANCE...............................................................P4

SPECIFICATIONS - SAMPLE REQUIREMENTS..............................................P4

SPECIFICATIONS - AMBIENT REQUIREMENTS.............................................P5

SPECIFICATIONS - DATA OUTPUT.................................................................P5

SPECIFICATIONS - UTILITY REQUIREMENTS ...............................................P5

SPECIFICATIONS - PHYSICAL.........................................................................P6

SPECIFICATIONS - OPTIONAL TYPE Z PURGE.............................................P6

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE.............P7

RETURNING PARTS TO THE FACTORY.........................................................P7

TRAINING ......................................................................................................P7

DOCUMENTATION............................................................................................P7

S

ECTION

1.1 SYSTEM DESCRIPTION ............................................................................1

1.2 TYPICAL APPLICATIONS...........................................................................1

1.3 PRINCIPLE OF OPERATION......................................................................2

1. I

NTRODUCTION

.............................................. 1

SECTION 2. INSTALLATION............................................... 4

2.1 GENERAL INFORMATION .........................................................................5

2.2 SAMPLE CONDITIONING...........................................................................5

2.3 LOCATION..................................................................................................5

2.4 UTILITIES AND SUPPLIES .........................................................................6

2.4.1 ELECTRICAL CONNECTIONS .....................................................6

2.4.1.1 Power.............................................................................6

2.4.1.2 Signal.............................................................................6

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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ONTENTS

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2.4.1.3 Alarm............................................................................. 6

2.4.2 GAS, LIQUID CONNECTIONS ..................................................... 6

2.4.2.1 Sample In...................................................................... 6

2.4.2.2 Sample Drain................................................................. 8

2.4.2.3 Reagent......................................................................... 8

2.4.2.4 Standard......................................................................... 8

2.4.2.5 Carrier Gas..................................................................... 8

2.4.2.6 Vent................................................................................ 9

2.4.2.7 Waste ............................................................................. 9

2.4.2.8 Condensate Trap Drain................................................. 9

2.5 INSTALLATION........................................................................................... 10

2.5.1 Mounting Instrument...................................................................... 10

2.5.2 Electrical ..................................................................................... 10

2.5.2.1 Power............................................................................. 10

2.5.2.2 Signal.............................................................................. 10

2.5.2.3 Alarm.............................................................................. 13

2.5.3 Piping ..................................................................................... 14

2.5.3.2 Drain............................................................................... 14

2.5.3.3 Standard........................................................................ 15

2.5.3.4 Reagent......................................................................... 15

2.6 OPTIONAL TYPE Z PURGE....................................................................... 15

SECTION 3. INITIAL START-UP..........................................16

3.1 START-UP PROCEDURE.......................................................................... 17

SECTION 4. OPERATION AND MAINTENANCE.....................22

4.1 OVERVIEW................................................................................................. 23

4.2 PREPARING REAGENT............................................................................. 24

4.3 REPLACING PUMP TUBES....................................................................... 26

4.4 CALIBRATION CHECK............................................................................... 28

4.5 IR ZERO, SPAN CHECK............................................................................ 30

4.6 TOC ZERO, SPAN CHECK........................................................................ 32

4.7 SEDIMENT REMOVAL............................................................................... 34

4.8 PUMP MOTOR BEARINGS........................................................................ 34

4.9 TOC ALARM............................................................................................... 34

4.10 PREPARATION FOR SHIPMENT............................................................ 35

4.11 CLEANING INFRARED ANALYZER OPTICAL UNIT............................... 38

4.12 CLEANING CONDENSATE TRAP ........................................................... 39

ii

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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SECTION 5. PREPARATION OF STANDARDS ...................... 41

5.1 STANDARDS PREPARATION....................................................................41

5.2 BACKGROUND TOC COMPENSATION ....................................................43

SECTION 6. CIRCUIT DESCRIPTIONS ................................. 47

6.1 GENERAL ...................................................................................................47

6.2 INPUT SIGNAL CONDITIONER..................................................................47

6.3 LINEARIZER................................................................................................ 47

6.4 ZERO AND SPAN .......................................................................................47

6.5 RECORDER OUTPUTS..............................................................................47

6.6 ALARM OUTPUT.........................................................................................48

6.7 DISPLAY .....................................................................................................48

6.8 POWER SUPPLY........................................................................................48

SECTION 7. TROUBLESHOOTING....................................... 49

S

ECTION 8. REPLACEMENT PARTS................................... 59

8.1 RECOMMENDED SPARE PARTS..............................................................59

8.2 REPLACEMENT PARTS (NUMERICALLY)................................................60

8.3 REPLACEMENT PARTS (ALPHABETICALLY)...........................................62

GENERAL PRECAUTIONS FOR HANDLING & STORING HIGH PRESSURE CYLINDERS
WARRANTY
FIELD SERVICE AND REPAIR FACILITIES

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

iii

ONTENTS

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FIGURES

1-1. Simplified Model 2100A Flow Diagram (TOC Version).............................. 3

1-2. Simplified Model 2100A Flow Diagram (TC Version)................................. 3

2-1. Inner Compartment.................................................................................... 7

2-2. Electrical Connection to PC Board............................................................. 7

2-3. Inner Panel Layout..................................................................................... 11

2-4. Opening Control Panel (loosen two panel fasteners)................................. 12

2-5. Block Wiring Diagram (115VAC)................................................................ 12

2-6. Block Wiring Diagram (230VAC)................................................................ 13

2-7. Purge Option Mounting.............................................................................. 16

3-1. Alarm Readout Button (press and hold while adjusting setpoint)............... 21

4-2. Removing Pump Head............................................................................... 27

4-3. Remove Old Pump Tube ........................................................................... 27

4-4. Connecting New Pump Tube..................................................................... 27

4-5. Fastening Tube Ends................................................................................. 27

4-6. Engaging Pump Shaft................................................................................ 27

4-7. Installing New Pump Tube......................................................................... 27

4-8. Positioning Pump Tube.............................................................................. 29

4-9. Installing Pump Head................................................................................. 29

4-10. Installing Knurled Screws......................................................................... 29

4-11. Straightening Pump Tube ........................................................................ 29

4-12. Set Switch to IR CAL ............................................................................... 31

4-13. Injecting Zero Gas.................................................................................... 31

4-14. Adjusting IR ZERO to 000........................................................................ 31

4-15. Injecting Span Gas................................................................................... 31

4-16. Adjusting IR SPAN Value......................................................................... 31

4-17. Set IR Switch To Normal.......................................................................... 31

4-18. Reagent Pump Switch ............................................................................. 32

4-19. Adjusting TOC ZERO............................................................................... 33

4-20. Sample Selector Valve............................................................................. 33

4-21. Turning Reagent Pump ON...................................................................... 33

4-22. Adjusting TOC SPAN............................................................................... 33

4-23. Infrared Analyzer Optical Unit - Exploded View....................................... 38

4-24. Condensate Trap Assembly..................................................................... 39

T

ABLES

iv

4-1. Application Data......................................................................................... 25

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

DRAWINGS (LOCATED IN REAR OF MANUAL)

655369 Outline and Mounting Dimensions, Model 2100A
655376 Piping Diagram, Model 2100A
660871 Block Wiring Diagram, 230VAC
660872 Block Wiring Diagram, 115VAC
837484 Schematic Diagram, Model 2100A
837519 Type Z Purge Option

ONTENTS

C

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

v

P

REFACE

SAFETY SUMMARY

To avoid explosion, loss of life, personal injury and damage to this equipment and
on-site property, all personnel authorized to install, operate and service the Model 340
Trace Moisture Analyzer should be thoroughly familiar with and strictly follow the
instructions in this manual. Save these instructions.

DANGER is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored

WARNING is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.

CAUTION is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.

NOTE is used to indicate installation, operation, or maintenance information which is
important but not hazard-related.

WARNING: ELECTRICAL SHOCK HAZARD

Do not operate without doors and covers secure. Servicing requires access to
live parts which can cause death or serious injury. Refer servicing to qualified
personnel.

For safety and proper performance this instrument must be connected to a
properly grounded three-wire source of power.

Alarm switching relay contacts wired to a separate power source must be
disconnected before servicing.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

P1

REFACE

P

WARNING: POSSIBLE EXPLOSION HAZARD

This analyzer is of a type capable of analysis of sample gases which may be
flammable. If used for analysis of such gases, the detection section of the
analyzer must be either in an explosion proof enclosure suitable for the hazard
classification of the gas, or protected by a continuous dilution purge system in
accordance with Standard ANSI/NFPA-496-1986 (Chapter 8) or IEC Publication
79-2-1983 (Section Three).

If explosive gases are introduced into this analyzer, the sample containment
system must be carefully leak checked upon installation and before initial
startup, during routine maintenance and any time the integrity of the sample
containment system is broken, to ensure that the system is in leak proof
condition. Leak check instructions are provided in Section 4.2.

Internal leaks resulting from failure to observe these precautions could result in
an explosion, causing death, personal injury or property damage.

WARNING: HIGH PRESSURE GAS CYLINDERS

Fuel, air and calibration gas cylinders are under pressure. Mishandling of gas
cylinders could result in death, injury or property damage. See General
Precautions for Handling and Storing High Pressure Cylinders, in the rear of this
manual.

CAUTION: PARTS INTEGRITY

Tampering or unauthorized substitution of components may adversely affect
safety of this product. Use only factory documented components for repair.

P2

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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WARNING: MERCURY HAZARD

The ultraviolet light generating lamp contains mercury. Lamp breakage could
result in mercury exposure. Mercury is highly toxic if absorbed through the skin
or ingested, or if the vapors are inhaled.

Handle lamp assembly with extreme care. If lamp if broken, avoid skin contact
and inhalation in the area of the lamp or the mercury spill.

]Immediately clean up and dispose of the mercury spill and lamp residue as
follows:

• Wearing rubber gloves and goggles, collect all droplets of mercury by

means of a suction pump and aspirator bottle with a long capillary tube.
(Alternatively, a commercially available mercury spill clean up kit, such
as J.T. Baker product No. 4439-01, is recommended.)

• Carefully sweep any remaining mercury and lamp debris into a dust

pan.

• Carefully transfer all mercury, lamp residue and debris into a plastic

bottle which can be tightly capped.

• Label and return to hazardous material reclamation center.

• Do not place in trash, incinerate or flush down sewer.

• Cover any fine droplets of mercury in non-accessible crevices with

calcium polysulfide and sulfur dust.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

P3

REFACE

P

S

PECIFICATIONS

- O

PERATIONAL

PRINCIPLE

Ultraviolet/persulfate oxidation to CO2

D

ETECTION METHOD

Non-Dispersive Infrared (NDIR)

TOC RANGE - SINGLE RANGE (PPM CARBON)

0 to 2 0 to 5 0 to 10
0 to 20 0 to 50 0 to 100
0 to 200 0 to 500 0 to 1000
0 to 2000 0 to 5000

SPECIFICATIONS - PERFORMANCE

R

EPRODUCIBILITY

1

R

ESPONSE TIME

±2% fullscale

Less than 5 minutes for 90% of fullscale for most ranges

SPECIFICATIONS - SAMPLE REQUIREMENTS

F

LOW RATE SAMPLE INLET

50 to 2000 ml/min. depending on sample availability and response required

F

LOW RATE SIDE STREAM

1.1 to 15 ml/min. depending on reactor range

I

NLET PRESSURE

Constant 2 psig minimum, 15 psig maximum at sample inlet

T

EMPERATURE

35°F to 160°F (2°C to 71°C)

S

USPENDED SOLIDS

Sample must be free of particles larger than 100 micro ns

C

HLORIDES

Up to 1000 ppm (wt)

1

±5% for 0 to 2, 0 to 500, and 0 to 5000 ppm. For better reproducibility, consult factory. Absolute accuracy of analysis

depends upon the accuracy of the calibration standards.

P4

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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P

S

PECIFICATIONS

TEMPERATURE

35°F to 122°F (2°C to 50°C)
Protect from heating effect of direct sunlight

H

UMIDITY

0 to 90% relative humidity

S

PECIFICATIONS

L

OCAL READOUT

Electroluminescent backlighted liquid crystal display (LCD) reading of organics
in ppm (carbon)

A

NALOG OUTPUT

– S

Voltage Output: 0 to 1 VDC; 0 to 10 mV DC

A

NALOG OUTPUT

– O

Current Output: 4 to 20 mA DC isolated, 500 ohm load maximum

A

LARM

Single 100% adjustable, high or low, DPDT 10A, 240 VAC (30 VDC) relay
contacts

- A

- D

TANDARD

PTIONAL

MBIENT REQUIREMENTS

ATA OUTPUT

SPECIFICATIONS - UTILITY REQUIREMENTS

P

OWER

P

OWER

C

ARRIER GAS

D

RAIN

V

ENT

R

EAGENT

– S

TANDARD

115 VAC ±10%, 50/60 Hz, 1 phase, 3 amps, 350 watts

– O

PTIONAL

230 VAC ±10%, 50/60 Hz, 1 phase, 1.5 amps, 350 watts

200 to 500 scc/min. nitrogen, 1/8-inch tubing (see Table 4-1 for pressure)

Open atmospheric: 1/2-inch minimum inner diameter
2 L/min. maximum, 1/2-inch NPT

Atmospheric operation only.
1 L/min. maximum 1/2-inch NPT gas flow
Connection normally not required

19 L/mo. (all ranges except 0-5000 ppm) to 47 L/mo. (0 to 5000 ppm)

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

P5

REFACE

P

S

PECIFICATIONS

- P

HYSICAL

ELECTRICAL CLASSIFICATION – STANDARD

General purpose (non-hazardous locations)

E

LECTRICAL CLASSIFICATION

– O

PTIONAL

Air Purge, Type Z, ANSI/NFPA 496 for Class I, Division 2 hazardous locations

ENCLOSURE

NEMA-3R

D

IMENSIONS

23.7 x 15.0 x 8.3 (600 x 380 x 210) H x W x D

W

EIGHT

(115 VAC) 60 lb. (27.2 kg)
(230 VAC) 65 lb. (29.5 kg)

S

HIPPING WEIGHT

(115 VAC) 75 lb. (34 kg)
(230 VAC) 80 lb. (36.3 kg)

SPECIFICATIONS - OPTIONAL TYPE Z PURGE

P

URGE GAS

Inert gas, such as nitrogen, supplied through 1/8-inch tubing at 20 psig

O

PERATING PRESSURE

.2 inch H2O

I

NLET PRESSURE

Constant 2 psig minimum, 15 psig maximum at sample inlet

T

EMPERATURE

35°F to 160°F (2°C to 71°C)

S

USPENDED SOLIDS

Sample must be free of particles larger than 100 micro ns

C

HLORIDES

Up to 1000 ppm (wt)

P6

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

REFACE

P

C

USTOMER SERVICE

For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:

, T

ECHNICAL ASSIST ANCE AND FIELD SERVICE

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

RETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call: Model Number, Serial Number, and Purchase Order Number or Sales Order

Number.

Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sende r, f re ight collect.

When returnin g any pro duct o r compon ent t hat has be en expo sed to a toxic, corrosi ve
or other hazardous material or used in such a hazardous environment, the user must
attach an appropriate Material Safety Data Sheet (MSDS.) or a written certification that
the material has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

USA

T

RAINING

A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the Current Operator and Service Training Schedule contact
the Technical Services Depart men t at:

Rosemount Analytical Inc.

Phone: [phone]

FAX: [phone]

D

OCUMENTATION

The following Model 340 Trace Moisture Analyzer instruction materials are available.
Contact Customer Service or the local representative to order.

081854 Instruction Manual (this document)

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

P7

I

NTRODUCTION

1

1.1 SYSTEM DESCRIPTION

The Model 2100A is a continuous, on-line organics analyzer for industrial water analysis
applications with fullscale ranges from 0 to 2 ppm to 0 to 5000 ppm total organic carbon.
This reliable, low maintenance, industry-proven analyzer offers a real-time, accurate
analysis of organic levels in a variety of process water streams.

This model utilizes continuously operating ultraviolet-promoted persulfate oxidation to
convert organic carbon to carbon dioxide. This CO2 is then measured by an accurate
non-dispersive infrared detector. Output is calibrated to read parts-per-million (ppm) carbon.
This cost effective, rugged industrial design provides fast response and simple operation.
The Model 2100A has been proven successful in a wide variety of applications.

1.2 TYPICAL APPLICATIONS

EMICONDUCTOR PLANTS

S

Reclaimed water
Deionized water plant input

HEMICAL/PETROCHEMICAL PLANTS

C

Cooling water
Waste water
Organic loading of process streams
Product loss monitoring

OOD/BEVERAGE PLANTS

F

Cooling water
Waste water
Condensate return
Ion exchange effluent
Rinse water

OWER PLANTS

P

Cooling water
Boiler feedwater
Condensate return
Waste water

ATER/WASTEWA TER PLANTS

W

Raw and finished water quality
Potable water
Effluent water

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

1

NTRODUCTION

I

1.3 PRINCIPLE OF OPERATION

Refer to Figures 1-1 (TOC Version) and 1-2 (TC Version). The Model 2100A uses ultraviolet
promoted persulfate oxidation with infrared detection to continuously determine
concentration of soluble, non-volatile reactive organics. When a sample containing organic
compounds is mixed with a persulfate solution and exposed to ultraviolet radiation, it is
oxidized to CO2, as shown in the following equation:

Organics + [S2O8] -2 + H2O
½ CO2 + [SO4] -2 + H2SO

UV

4

The concentration Of CO2 is then determined with an infrared analyzer. If dissolved CO
and inorganic carbon are removed prior to oxidation, then the CO2 generated after oxidation
is indicative of the organics content in the sample.

Sample is introduced continuously into the Model 2100A through a sample bypass either by
means of process pressure or an optional sample pump. A sidestream for analysis is
continuously pumped at a constant rate and acidified with a sodium or ammonium
persulfate/phosphoric acid solution. The phosphoric acid reacts with any inorganic carbon
compounds (i.e., carbonates and bicarbonates) which may be present to form CO2. This
acidified solution is then sparged with carrier gas (nitrogen) to remove the CO2 and is
passed through a liquid/gas separator to vent the CO2. The liquid is introduced to the
reaction chamber where it is exposed to high intensity (184.9 nm) ultraviolet light.

The UV radiation catalyzes the persulfate oxidation of the remaining organic carbon to CO2.
The CO2-containing carrier gas is passed through a condensate trap to remove moisture,

and then through a non-dispersive infrared analyzer which measures the CO2 concentration.

2

In the TC Version, both organic and inorganic carbon are measured. The sparge system is
removed from this configuration, which allows all gases to pass through the infrared
detector.

The Model 2100A electronics linearize and scale the infrared detector signal to equate to
ppm carbon organics concentration which is read out continuously on the digital display
while simultaneously transmitting an analog signal proportional to the ppm carbon reading.
This proven concept provides quick, real-time response while maintaining high accuracy.

2

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

NTRODUCTION

I

IGURE

F

1-1. S

IMPLIFIED MODEL

2100A F

LOW DIAGRAM

(TOC V

ERSION

)

IGURE

F

748263-E Rosemount Analytical March 2001

1-2. S

IMPLIFIED MODEL

2100A F

LOW DIAGRAM

Model 2100A Process Total Organic Carbon Analyzer

(TC V

ERSION

)

3

NTRODUCTION

I

NOTES

4

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

I

NSTALLATION

2

2.1 GENERAL INFORMATION

This section contains instructions on site requirements, utilities, pre-operation checkout,
installation and pre tart-up preparations for the Model 2100A Process Total Organic Carbon
Analyzer.

2.2 SAMPLE CONDITIONING

Application parameters of the Model 2100A are influenced by the following typical user
criteria:

• Measurement objective

• Physical plant arrangement

• Nature of test sample.

Performance of the Model 2100A depends upon the integrity of the sample. Therefore, each
Model 2100A system installation may be unique with respect to conditioning of the sample.

The sample flow rate supplied to the Model 2100A by a typical sample system is many
times greater than the minimum flow required. This serves to:

• Reduce lag time

• Minimize change in sample composition

• Optimize functioning of basic sample conditioning elements

• Optimize compatibility with commercially available pumps and pipe sizes

The analyzer sample inlet system, therefore, is designed to handle an input flow rate of 2
L/min maximum. A sidestream flow of 1. 1 to 15 ml/min is taken for analysis from the flowing
inlet sample.

Maximum admissible particle size in the sample supplied to the unit is 100 micron diameter.

2.3 LOCATION

The installation site must be near the sample access point to assure good sample integrity
and minimum input lag time. The location must be level, covered and adequately enclosed
to provide the unit with good ventilation but without high concentrations of dust or dirt in the
air. Ambient operating temperature range is 35°F to 122°F (2°C to 50°C) at 90% maximum
relative humidity. The Model 2100A must be isolated from strong vibrations (as may be
caused by large motors, pumps, etc.) and protected from the heating effect of direct
sunlight.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

5

NSTALLATION

I

Note
The standard Model 2100A is designed for installation only in unclassified,

non-hazardous locations. If equipped with an optional air purge system and installed
and operated per Type Z of standard ANSI/NFPA 496, the Model 2100A may be
located in a Class I, Division 2 classified location as defined in the National Electrical
Code (ANSI/NFPA 70).

Actual outside dimensions of the Model 2100A are found in Table 1-1 and drawing 655369.

2.4 UTILITIES AND SUPPLIES

2.4.1 ELECTRICAL CONNECTIONS

2.4.1.1 P

A 115 VAC, 50/60 Hz (optional 230 VAC, 50/60 Hz), 1 phase, 15 A service line with ground
is required. Protection by circuit breaker or fuse is necessary. A 14-inch power conduit
opening is located on the top right side (frontal view, this and subsequent references) of the
Model 2100A cabinet. Power should be wired to the power terminal strip (Figure 2-1).

2.4.1.2 S

Analog output signals of 0 to 1 VDC, 10 mV DC, or optional 4 to 20 mA DC are provided for
external stripchart recorders or other signal processing equipment. A separate 1/2-inch
conduit opening is located on the top right side of the Model 2100A cabinet for signal wiring.
Signal should be wired from terminal board TB1 (Figures 2-1, 2-2). To prevent electrical
interference, signal wiring should be run in conduit separate from the power wiring. W here
possible, signal cable should be a twisted pair with overall shield and outer insulating jacket.
The shield should be grounded at one end only. W hen not used, the signal conduit opening
should be plugged with an appropriate watertight plug such as Caplugs part number BP 7/8.

2.4.1.3 A

The Model 2100A has one set of fully adjustable 10 A, 240 VAC (30 VDC), DPDT alarm
contacts for either high or low TOC alarming. If used, the alarm wiring should be connected
to TB2 (Figure 2-2). Either the power or the analog signal conduit opening may be used,
depending upon the voltage level present in the users alarm system.

OWER

IGNAL

LARM

2.4.2 GAS, LIQUID CONNECTIONS

2.4.2.1

The process sample must be supplied at a small positive, constant pressure (2 psig min., 15
psig max.). A 1/4-inch NPT sample inlet connection is provided on the lower left side of the
Model 2100A cabinet. Refer to drawing 655369 for recommended installation. For
installations where pressure is greater than 2 psig, some means of throttling and flow
indication such as a rotameter with throttling valve is desirable. Sample flow may be in the

6

SAMPLE IN

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

NSTALLATION

I

range of 50 to 2000 ml/min, with a preferred flow of at least 1000 ml/min to minimize sample
transport lag time.

The sample must not contain particles larger than 100 microns in diameter.

IGURE

F

IGURE

F

2-1. I

2-2. E

NNER COMPARTMENT

LECTRICAL CONNECTION TO

PC B

OARD

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

7

NSTALLATION

I

2.4.2.2 S

AMPLE DRAIN

A 1/2-inch NPT connection is provided on the left side of the Model 2100A cabinet. This
drain should slope directly to an open atmospheric drain, using 1/2-inch minimum O.D.
tubing or 1/2-inch minimum diameter pipe with no pockets or obstructions which might
introduce back pressure at the analyzer drain connection. See drawing 655369 for
recommended installation. A special 1/2-inch elbow with vent hole is supplied separately for
making this drain connection.

2.4.2.3 R

EAGENT

A 1/8-inch tubing connection is located at the left side of the Model 2100A cabinet for
connection to the persulfate reagent reservoir supplied with the instrument. A continuous
10-foot length of 3/16-inch O.D.

Teflon tubing runs through this fitting for connection to the reagent reservoir. To connect the
reservoir, drill a 1/4-inch hole in the center of the reservoir cap and insert the Teflon tube
into the hole until the tube reaches the bottom of the reservoir. Stainless steel tube ferrules
attached to the tube end act as a weight to prevent the tube from floating. See drawing
655369 for proper installation. Refer to Section 4.2 and Table 4-1 for special instructions
about reagent preparation.

CAUTION: CORROSION HAZARD

Do not use metal tubing or fittings for reagent connection.

2.4.2.4 S

TANDARD

This 1/8-inch tubing connection, located on the lower left side of the Model 2100A cabinet,
is for introducing a prepared calibration standard for calibration of the analyzer, or for
introducing a "grab sample" for analysis. For the recommended calibration standard, see
Table 4-1 and refer to Section 5. A continuous 4 to 5-foot length of Teflon tubing runs
through this connection directly to the sample select valve. The free end of this tube should
be inserted into a sample container at atmospheric pressure. A stainless steel nut and
ferrules attached to the free end of this tube act as a weight to prevent the tube from float­ing. The sample is pumped out of the container by the sample pump internal to the analyzer
when the pump is running and the sample selector valve is rotated to the "Standard"
position. See Section 3, INITIAL START-UP, and Section 4, OPERATION and
MAINTENANCE, for operational details. See drawing 655369 for recommended installation.

2.4.2.5 C

ARRIER GAS

A 1/8-inch tubing connection is located on the lower left side of the Model 2100A for a
suitable carrier gas. A 1/8-inch tube is recommended but 1/4-inch tubing with a 1/8-inch
adapter may be necessary to avoid pressure drop if the distance from gas supply to
instrument exceeds 5 to 10 feet.

8

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

NSTALLATION

I

Carrier gas may be clean, dry CO2-free nitrogen. It should be supplied at 75 to 100 psig at
instrument inlet. Set the internal carrie r gas regulator according to requirements un ique to
each individual instrument, as outlined on the Data Sheet at the back of the manual. Carrier
gas consumption is between 200 and 500 cc/min depending upon the TOC fullscale range.
See drawing 655369 for recommended installation.

2.4.2.6 V

ENT

A 1/2-inch tubing vent connection is located on the lower left side of the Model 2100A. This
vent carries the combined flow of drying gas and CO2-containing carrier and sparge gas.
Normally no tubing is required for this vent. In fact, the preferred installation requires no
external tubing or piping connected to the vent connection. If it is necessary to route this
vent outside, 1/2-inch O.D. minimum tubing or 1/2-inch tubing minimum pipe should be
used. The tubing should be as short as possible and must slope downward throughout, with
no pockets where condensation might collect and cause varying back pressure. See
drawing 655369.

CAUTION: BACK PRESSURE HAZARD

The "Sample Drain" and "Waste Drain" must not be connected together. Both
drains should be run separately into a common open atmospheric drain. These
lines must slope all the way to the open drain, with no pockets or obstructions
which might introduce back pressure at the analyzer drain connection. Only the
special vented male elbow supplied with the analyzer should be used for making
the first connection to the analyzer "Waste Drain."

2.4.2.7 W

ASTE

A 1/2-inch NPT waste drain connection is located on the lower left side of the Model 2100A.
This drain must be connected to a 1/2-inch minimum plastic or 316SS tubing or pipe, and
must continuously slope downward unobstructed to an open atmospheric drain. To assure
proper venting of this drain, a special 1/2-inch plastic male elbow with a drilled vent hole is
provided with the analyzer. Use only this connector for the first waste fitting out of the
analyzer.

Note
Use only plastic or 316SS material in the "Waste Drain" line. This line contains a

persulfate salt, which will corrode most metals. Do not use copper or brass.

2.4.2.8 C

ONDENSATE TRAP DRAIN

The self-draining condensate trap requires a 3/8" I.D. hose attached to its drain stem. See
drawing 655369. The hose should be directed to an open drain or container. Allow water to

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

9

NSTALLATION

I

drain freely. Keep the drain hose above the water level of the drain or container. Do not
obstruct the drain stem.

2.5 INSTALLATION

2.5.1 M

OUNTING INSTRUMENT

1. Find a suitable location to mount the Model 2100A as discussed in Section 2.3.

2. The dimensional drawing for the unit is drawing 655369. Use either the dimensional
drawing or the module itself to locate and drill analyzer mounting holes. Mounting
brackets are provided with the analyzer.

2.5.2 E

LECTRICAL

Refer to Figure 2-4. Turn OFF (lower portion of switch pushed in) the "MAIN POWER,"
"LAMP," and both "PUMP" switches located on the control panel inside the analyzer. Open
this panel (Figure 2-5) and make all electrical connections to the analyzer as follows.

WARNING: ELECTRICAL SHOCK HAZARD

Installation and servicing requires access to shock hazard level voltages which
can cause death or serious injury. Refer servicing to qualified personnel.

For proper performance and safety, this instrument must be connected to a
properly grounded three-wire source of electrical power.

2.5.2.1 P

OWER

Refer to Figures 2-1 and 2-6 (115 VAC) or 2-7 (230 VAC).
Connect power to the terminal strip mounted in the upper right corner of the back panel. For

115 VAC instruments, connect "Hot" line to "HOT" terminal and "Neutral" line to "NEU"
terminal. For 230 VAC instruments, which are typically not polarized, connect the "Ground"
line to "GND" terminal and the other two lines to the "Ll" and “L2" terminals.

2.5.2.2 S

IGNAL

Refer to Figures 2-1 and 2-2.
Connect Analog Signal wiring to the appropriate output signal terminals of the electronics

board, which is located under the top panel of the Model 2100A. Since the board is rotated
1800 upon mounting, these terminals, from left to right, read "420 mA +", "4-20 mA –“,
"GND", "0-10 mV", and "0-1 V". The terminals marked "0-1 V" and "0-10 mV" are positive,
and "GND" is negative. The "4-20 mA " ter min al s are electr i cal l y isolated.

10

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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Note
"0-1 V" and "0-10 mV" outputs are present on all instruments. A 4 to 20 mA signal is

present only if the optional 4 to 20 mA output has been purchased. This output is
obtained from a plug-in module which may be added at a later time if desired.

A shielded, twisted-pair cable is recommended for all signal wiring. The shield should be
grounded at one end only, normally at the recorder or other receiver end.

IGURE

F

748263-E Rosemount Analytical March 2001

2-3. I

NNER PANEL LAYOUT

Model 2100A Process Total Organic Carbon Analyzer

11

NSTALLATION

I

IGURE

F

2-4. O

PENING CONTROL PANEL (LOOSEN TWO PANEL FASTENERS

)

IGURE

F

12

2-5. B

LOCK WIRING DIAGRAM

(115VAC)

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

NSTALLATION

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2.5.2.3 A

LARM

Refer to Figures 2-1 and 2-2.

WARNING: ELECTRICAL SHOCK HAZARD

Alarm switching relay contacts wired to a separate power source must be
disconnected before servicing.

Connect alarm wires to the appropriate terminals (TB2) located on the electronics board.
These are DPDT contacts capable of switching up to 10 A at 240 VAC. They may be used
for driving alarm annunciators, lights, horns or other devices. Power must be supplied by
your alarm actuating circuit, if needed.

IGURE

F

748263-E Rosemount Analytical March 2001

2-6. B

LOCK WIRING DIAGRAM

(230VAC)

Model 2100A Process Total Organic Carbon Analyzer

13

NSTALLATION

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2.5.3 P

IPING

Refer to drawing 655369.
To maintain sample integrity, the quality of the input samp le line is very imp ortant . The input

line should be clean and made from an inert material. New Teflon or stainless steel tubing is
strongly recommended.

Connect a 1/4-inch line from sample point to the sample inlet of the manifold. It is
recommended that a flowmeter with a throttling valve be installed in this line for flow control.
Desired flowrate is 1 L/min, but may be 50 to 2000 ml/min, depending upon desired
response time and sample availability.

CAUTION

Do not turn on sample until installation is complete.

2.5.3.2 D

RAIN

Refer to drawing 655369.
The Model 2100A has two drains located on the lower left side of the analyzer and a drain

from the condensate trap. The two-drain system was designed to eliminate sample con­tamination in those cases when it is desired to return the sample to the water system.

The drain designated "waste" contains oxidation products and persulfate not found in the
sample stream and MUST NOT be returned to the water system. The drain designated
"Sample Drain!' contains only process sample and may be returned to the water system.

If the sample drain is to be used in a sample return configuration, the drain line must meet
the same criteria as the sample line. If the sample overflow is directed to a drain, then the
material used to pipe the excess sample to the drain is not critical.

1. Connect a 1/2-inch. O.D., 10-ft. maximum length line from the "Sample Drain" to an open
drain.

2. Connect a 1/2-inch line to the "Waste" drain located on the lower left side of the cabinet.
The other end of the line should be routed to an appropriate open drain. This is a waste
line containing oxidized compounds and the persulfate oxidation medium.

14

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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CAUTION: BACK PRESSURE HAZARD

The drain lines must not be connected together before entering the open drain.
Connecting the drain lines or using a sealed drain can cause back pressure,
leading to excessive signal noise or actual flooding and damage to the
instrument.

Also, the Sample Drain line should drain freely to an open drain if possible. Do
not bend line more than 45 degrees from the vertical position because it may
cause excessive pressure.

Any other condition which would cause back pressure in the drain lines must be
avoided.

3. Connect a 1/2-inch line to the condensate trap drain. The other end of the line should be
routed to an appropriate open drain. This is a waste line that may contain small amounts
of oxidized compounds and the persulfate oxidation medium.

2.5.3.3 S

TANDARD

The "Standard" inlet located on the lower left side of the cabinet is used to introduce a
calibration solution or to introduce a "grab" sample for analysis. Turn the selector valve on
the inner panel to "Standard" for oper a ti on o f the "Stan dar d" inl et.

The Teflon tube may be inserted into a glass bottle or other calibration standard container.

2.5.3.4 R

EAGENT

Insert the 1/16-inch Teflon tube through the reagent reservoir cap into the container until the
tube end rests on the reservoir bottom. Do not use metal tubing or fittings for this line. The
reagent will react with most metals except 316SS. Refer to Section 4.2 for reagent
preparation procedures.

2.6 OPTIONAL TYPE Z PURGE

Refer to Figure 2-8, and drawings 655369 and 837519 in Appendix A. The Model 2100A
can be fitted with an optional Type Z purge (PN 837519). This option, which is installed on
the instrument's right side, allows the unit to be placed in a Class I, Division 2 hazardous
location per Standard ANSI/NFPA 496.

The Type Z purge supplies an inert gas, such as nitrogen, to the interior of the instrument
casing. Administer purge gas to flowmeter at 20 psig. Adjust flowmeter for operation at .2
inch H2O.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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NSTALLATION

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WARNING: POSSIBLE EXPLOSION HAZARD

For instruments equipped with the optional Type Z air purge installed in a Class
1, Division 2 (or equivalent) Hazardous Location, enclosure shall not be opened
unless the area is known to be non-hazardous or unless all devices within have
been de-energized. Power shall not be restored after enclosure has been opened
until enclosure has been purged for 10 minutes.

IGURE

F

16

2-7. P

URGE OPTION MOUNTING

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

S

TARTUP PROCEDURE

3

3.1 START-UP PROCEDURE

The purpose for this section is to provide step-by-step instructions, as follows, for first-time
start-up of the unit.

1. A selector valve, located on the inner panel, is labeled "Standard" and "Process
Sample". Turn this valve to the "Standard" position. Flow process sample through the
sample inlet at a rate greater than 50 ml/min but not greater than 2000 ml/min. Check for
leaks both inside and outside and correct any found. Allow the system to flush for at
least one hour while proceeding with start-up.

2. Turn on drying gas, then carrier gas, and check for leaks using SNOOP PN 837801) or
other leak detection solution.

3. Loosen 2 panel fasteners (Figure 2-5). Open inner panel and set carrier pressure
according to the Data Sheet at the back of the manual.

Note
This setting will change as the analyzer warms up and should be reset after about 2
hours.

4. Ensure that all switches on the inner panel are off (lower portion of switch pushed in).

5. Turn on external power to the instrument.

6. Turn on power switch ("on" position to the left) on the left side of the electronics board
behind inner panel at the top of the unit.

7. Turn on main power switch (upper portion of switch pushed in) on upper right corner of
panel.

At this point, heater, heater fan and front panel digital display on the front of the outer
door should be operating.

8. Close inner panel and allow instrument to warm while proceeding with start-up.

9. Fill reagent reservoir, a 20 L container. (See Section 4.2, PREPARING REAGENT).

10. Install the reactor cap/lamp assembly to the top of the reactor. Ensure the rubber septum
in the glass tube faces towards the front of the instrument. Install retaining springs to the
cap and plug in lamp cord to lamp power outlet (Figure 2-4). Connect rubber tubing at
lower end of condenser tubing over the rear glass tube on the reactor cap.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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TARTUP PROCEDURE

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CAUTION: INSTRUMENT DAMAGE

Do not run pumps without carrier gas flow. Damage to the instrument can occur
if this requirement is not observed.

11. Fill reagent reservoir, a 20 L container. (See Section 4.2, PREPARING REAGENT).

12. Install the reactor cap/lamp assembly to the top of the reactor. Ensure the rubber septum
in the glass tube faces towards the front of the instrument. Install retaining springs to the
cap and plug in lamp cord to lamp power outlet (Figure 2-4). Connect rubber tubing at
lower end of condenser tubing over the

CAUTION: GLASSWARE HAZARD

This instrument utilizes numerous vessels and other components made of
glass. These components are fragile and should be handled carefully to avoid
breakage. During installation or maintenance, wear face shield or eye goggles,
gloves, and lab coat or long-sleeved clothing. In the event of breakage,
immediately pick up and properly dispose of any large pieces. Use a suitable
wet/dry shop-type vacuum machine to remove fine pieces. If the UV lamp is
broken, refer to Mercury Hazard Warning below.

WARNING: MERCURY HAZARD

The ultraviolet light generating lamp contains mercury. Lamp breakage could
result in mercury exposure. Mercury is highly toxic if absorbed through the skin
or ingested, or if the vapors are inhaled.

Handle lamp assembly with extreme care. If lamp is broken, avoid skin contact
and inhalation in the area of the lamp or the mercury spill.

Immediately clean up and dispose of the mercury spill and lamp residue as
follows:

Wearing rubber gloves and goggles, collect all droplets of mercury by means of
a suction pump and aspirator bottle with a long capillary tube. (Alternatively, a
commercially available mercury spill clean up kit, such as J.T. Baker product
No. 4439-01, is recommended.) Carefully sweep any remaining mercury and
lamp debris into a dust pan. Carefully transfer all mercury, lamp residue and
debris into a plastic bottle which can be tightly capped. Label and return to
hazardous material reclamation center. Do not place in trash, incinerate or flush
down the sewer. Cover any fine droplets of mercury in non-accessible crevices
with calcium polysulfide and sulfur dust.

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March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

TARTUP PROCEDURE

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WARNING: INTERNAL ULTRAVIOLET LIGHT HAZARD

Ultraviolet light from the reactor lamp can cause permanent eye damage. Do not
look directly at the ultraviolet source in the reactor for prolonged periods. Use of
ultraviolet filtering glasses is recommended. Never operate the lamp outside the
reactor.

Additionally, the lamp may break if fluid flow is interrupted (allowing the lamp to
heat up) and then reintroduced to the hot lamp.

WARNING: HAZARDOUS AND CORROSIVE CHEMICAL

This instrument utilizes a user provided chemical reagent which is an aqueous
solution (14 to 40%) of either sodium persulfate, Na2S2O8, or ammonium persul­fate, (NH4)2S2O8, acidified with concentrated phosphoric acid, H3P04.

The reagent solution and its constituent chemicals are strong oxidizing agents
and are highly corrosive. They can cause severe skin burns and eye damage
upon contact. Ingestion could be fatal. Vapors can be very irritating to the skin,
mucous membranes, eyes and respiratory tract.

Reagent leakage can cause severe corrosion damage to the instrument's
enclosure and/or components and could create an electrical shock hazard. The
instrument should be thoroughly checked for leaks during installation and
start-up, routinely thereafter, and any time the integrity of the reagent contain­ment system is disrupted (e.g., for tube or fitting replacement).

Chemical salt encrustation at joints or fittings is an early symptom of reagent
leakage. If evidence of leakage is discovered, the instrument should be imme­diately shut down and the leak repaired. Salt encrustation is normal at the
reactor top interface. Salt buildup must be removed periodically to avoid
collection on the case bottom, where the salt will damage the instrument en­closure due to reaction with moisture.

Refer reagent preparation, installation and service to qualified chemical
technicians and observe all precautions noted in the safety messages located in
appropriate sections throughout this manual.

11. Remove silicone rubber septum from reactor cap and fill reactor with distilled or
deionized water. Observe carrier gas bubbling up through reactor.

12. Replace septum.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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TARTUP PROCEDURE

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13. Insert the reagent tubing into the 20 L reagent container (see step 9 above), and turn on
reagent pump.

Note
It will take several minutes for the first drops of reagent to reach the sparger. The

reagent flowrate is only approximately 1/2 ml/min. Do not run reagent pump without
the sample pump for long periods as reagent may froth and travel upstream in the
condenser tube.

14. Observe whether reagent/gas mixture is being blown into sample inlet sparger on the
side of the reactor. If not, pull on both pump tube ends while the pump is rotating. Wait
until reagent pump is primed and reagent/gas mixture is noted before proceeding.

15. Inse rt the standard line into a container of distilled or deionized water and set Sample
Selector Valve to "Standard" positi o n.

16. Turn on standard pump and ensure that flow has increased into sparger (signifying that
pump is drawing water from sample container).

17. After approximately an hour, switch IR Calibrate switch to "Calibrate." Open inner panel,
check carrier gas pressure, and reset if necessary. Close inner panel. Wait 10 to 15
minutes before proceeding.

18. Calibrate the IR analyzer zero and span. (Section 4.5, IR ZERO, SPAN CHECK).

19. Switch IR Calibrate switch to "Nor mal" and turn on UV lamp. At this point, the digital
reading can be expected to increase, perhaps off scale, until all organics in the reactor
are oxidized.

20. When TOC reading stabilizes (about 1/2 hr.), the standard sample tubing has been
adequately flushed.

21. Set TOC zero and span (See Section 4.6, TOC ZERO, SPAN CHECK).

22. Connect an accurate digital multimeter (DMM) or a recorder to the analog output
terminals. Adjust R12 for correct 0 to 1 VDC output or R44 for correct 0 to 10 mV DC
output (Figure 2-2). If you have the optional 4 to 20 mA output, set R44 to its lowest
setting and short the 0 to 10 mV output to ground. Adjust the 4 to 20 mA zero adjust for
4 mA output.

Note
A digital multimeter must be in series with other devices connected to this

output, and total output loop resistance must not exceed 500 ohms.

23. Remove short from 0 to 10 mV terminals, and adjust R44 for 0 to 10 mV reading which
corresponds to the digital reading. Then adjust the 4 to 20 mA "span" adjust for correct
output.

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March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

TARTUP PROCEDURE

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24. Remove digital multimeter and reconnect any output wires.

25. Press and hold alarm readout button (Figure 3-1) while adjusting R6 (Figure 2-2) for
correct alarm setting on digital display.

Note
PC board is mounted upside down at the top of the instrument, inside inner-

panel.

26. Close inner panel.

27. Turn sample select valve to "Process Sample" and close front door.

28. From this point on, inner panel should remain closed. Allowing the
temperature-controlled compartment to cool for any period of time may cause water
condensation in the dryer.

The analyzer is now ready for analysis of the process stream.
IR and TOC zero and span checks should be repeated after the first 24 hours of operation.

IGURE

F

748263-E Rosemount Analytical March 2001

3-1. A

LARM READOUT BUTTON (PRESS

AND HOLD WHILE ADJUSTING SETPOINT

)

Model 2100A Process Total Organic Carbon Analyzer

21

TARTUP PROCEDURE

S

NOTES

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March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

O

PERATION AND MAINTENANCE

4

4.1 OVERVIEW

The Model 2100A is designed for reliable, low-maintenance operation, requiring the
following routine maintenance.

Normal maintenance consists of:

• DAILY internal visual check for leaks and loose tubing,

• Replenishing reagent, (as required)

• Replacing two pump tubes, (every 6 months)

• Checking calibration, (as required)

• Removing reactor sediment, (as required)

• Cleaning IR analyzer, (as required)

These procedures are outlined in this section. They should be followed to ensure analyzer
life and performance.

WARNING: HAZARDOUS CHEMICALS

Sodium persulfate (Na2S2O8) and ammonium persulfate [(NH4)2S2O8)] are strong
oxidizing agents that may cause fire if placed in contact with other materials.
These chemicals and phosphoric acid (H3PO4) are corrosive and may cause se­vere burns if their dust or fumes are exposed to skin, eyes, or mucous
membranes, or if they are inhaled.

Use in vent hood or in a well ventilated location. Wear eye goggles, rubber
gloves and lab coat when handling all hazardous chemicals.

In the event of contact, flush eyes with water for at least 15 minutes. Flush skin
areas with plenty of water. Obtain medical aid immediately.

Refer to the Material Safety Data Sheet, supplied by the chemical manufacturer,
for specific information about each chemical.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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PERATI ON AND MAINTENANCE

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4.2 PREPARING REAGENT

The reagent reservoir (5 gal.) supplied with the instrument will hold enough reagent
(customer supplied) for up to four weeks of operation, depending on the analyzer's range.
Reagent flow is 26 ml/hr. to 65 ml/hr. depending on analyzer range.

To prepare the reagent, refer to Table 4-1 for correct reagent composition, and proceed as
follows.

1. Measure out one liter of deionized water.

2. Add sodium or ammonium persulfate [Na2S2O8 or (NH4)2S2O8] and stir until all crystals
are dissolved (use 140.0 grams for 14% or 400 grams for 40%).

CAUTION: DISSOLVE COMPLETE
USE SPECIFIED CHEMICALS ONLY

Be sure all crystals are completely dissolved. Any un-dissolved crystals will
cause excessive wear and premature failure of the reagent pump tube. They may
also plug instrument tubing.

Do not use potassium persulfate as a substitute for sodium or ammonium
persulfate. Potassium persulfate is less soluble. Therefore, it may leave
undissolved crystals or cause crystals to drop out of solution if ambient
temperature decreases. These crystals will cause the above-noted problems.

3. Add 5 ml of concentrated phosphoric acid (H3PO4) and stir.

4. Repeat this procedure until at least 10 liters of solution are prepared.

Alternatively, the reagent may be prepared in one batch, but a great deal of agitation will be
required to dissolve all of the persulfate. A mechanical stirrer (plastic or stainless steel) will
aid this procedure.

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March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

PERATION AND MAINTENANCE

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Recommended

TOC

Range

(fullscale)

IR Range

(fullscale)

Sample
Pump Head
(Model No.)

Persulfate

Reagent

Conc. Type

2

Carrier Gas

Pressure

(psig)

3

Restrictor

(color)

Calibration

Standard

(ppm)

KHP Sucrose

2 0.2 % 7016 14% Sodium 10 Red 1.8 1.8
5 0.2 % 7016 14 % Sodium 15 Red 4.5 4.6
10 0.2 % 7016 14 % Sodium 24 Red 9.0 9.0
20 0.2 % 7014 14 % Sodium 14 Blue 1810 18.0
50 1 % 7014 14 % Sodium 12 Red 45.0 45.0
100 1 % 7014 14 % Sodium 20 Red 90.0 90.0
200 1 % 7014 14 % Sodium 22 Blue 180 180
500 1 % 7013 14 % Sodium 16 Blue Note
1000 10% 7013 14 % Sodium 10 Red Note
2000 10% 7013 40 % Ammonium 10 Red Note
5000 10% 7013 40 % Ammonium 12 Red Note

4

450

4

900

4

1800

4

4500

NOTE: Settings are approximations only. Isopropyl alcohol not recommended for
calibration.

ABLE

T

4-1. A

PPLICATION DATA

2

Sodium persulfate is Na2S208 and ammonium persulfate is (NH4)2S208.

3

±20 %.

4

KHP not recommended for calibration at higher ranges but preferred over sucrose at lower ranges.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

25

PERATI ON AND MAINTENANCE

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4.3 REPLACING PUMP TUBES

CAUTION: REPLACE PUMP TUBES REGULARLY

A pump tube can fail in one of two ways: it may collapse or rupture. A collapsed
tube will decrease flow rate or stop flow completely. A ruptured tube will also
stop flow. More importantly, it will leak corrosive reagent into pump internals,
resulting in pump failure and increased pump tube wear. Therefore, it is
important to adhere strictly to a six-month pump tube replacement schedule.
Instrument warranty does not cover pump internals damaged by corrosion.

The pump tubes can be expected to last for about twelve months of normal operation. To
prevent unexpected analyzer shut- down or possible pump damage, the tubes should be
replaced every six months.

Figures 4-1 through 4-11 illustrate the procedure for replacing pump tubes. To replace them,
do the following procedure.

1. Turn 3-way valve in instrument to standard position. Pull standard and reagent lines
from respective bottles. Allow pumps to run for 15 minutes to flush liquid from lines.
Turn off PUMP POWER switches, and shut off carrier gas supply.

This step will prevent unwanted
backflow and possible reagent con­tamination during this procedure.

2. Loosen both knurled screws holding
the pump head together (Figure 4-1).

3. Pull off the front half of the pu mp head
(Figure 4-2).

4. Pull out the old pump tube (Figure 4-3).

5. Replace one end of tubing at a time (to
prevent improper re-connection) and
secure the new tubing on analyzer
tubing with two Ty-Raps on each end
to stop leakage (Figures 4-4 and 4-5).

6. Rotate and push the pump roller
assembly toward the inner back panel
to ensure that the assembly shaft is

IGURE

F

4-1. P

UMP HEAD SCREWS

fully engaged (Figure 4-6).

7. Place the new tube over the rollers while keeping tension on the tube toward the right
side and remembering that pump outlet is at top, inlet at bottom (Figure 4-7).

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March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

PERATION AND MAINTENANCE

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IGURE

F

IGURE

F

4-2. R

4-3. R

EMOVING PUMP HEAD

EMOVE OLD PUMP TUBE

IGURE

F

IGURE

F

4-5. F

4-6. E

ASTENING TUBE ENDS

NGAGING PUMP SHAFT

IGURE

F

748263-E Rosemount Analytical March 2001

4-4. C

ONNECTING NEW PUMP TUBE

IGURE

F

Model 2100A Process Total Organic Carbon Analyzer

4-7. I

NST ALLING NEW PUMP TUBE

27

PERATI ON AND MAINTENANCE

O

8. With left thumb, press the new pump tube completely under each roller, being careful
not to twist or kink the tube, or disengage the roller shaft (Figure 4-8).

9. Holding the tubes in the inlet and outlet grooves in the pump head, reinstall the pump
head half, making sure that the pump tube is not pinched between the two pump head
halves (Figure 4-9).

10. Install the knurled screws (Figure 4-10).

11. Firmly pull on each set of pump tube ends to remove any kinks or twists from the tube
(Figure 4-11).

12. After both pump tubes are re placed, turn on carrier gas supply and verify gas flow
through the reactor vessel. Turn on PUMP POWER switches. While the pumps are
running, again pull on each pump tube end to remove kinks or twists (Figure 4-11).

WARNING: POSSIBLE INSTRUMENT DAMAGE

Operation of reagent and sample pumps without carrier gas flow can cause
damage to the instrument.

13. If pump moves and makes a clicking sound, disassemble the front half of pump head,
and seat pump tubing.

Note
After a pump tube change, wait 2 hours for warm-up and recalibrate the

analyzer.

4.4 CALIBRATION CHECK

A complete calibration check should be performed periodically at startup and on a daily
basis until confidence in longer periods of time has been established.

A calibration check is done in two phases: (1) IR zero and span check and (2) TOC zero
and span check.

Note
Some analyzer internal components are temperature 8ensitive. For this reason,

the analyzer's inner compartment is heated to a controlled temperature
If the inner panel has been opened for maintenance, the panel should be closed
for at least two hours to allow for temperature stabilization before proceeding
with a calibration check. At initial start-up time, a slightly longer period
temperature stabilization may be required before final calibration.

of

130

°°°°

F.

of

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March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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IGURE

F

IGURE

F

4-8. P

4-9. I

OSITIONING PUMP TUBE

NSTALLING PUMP HEAD

IGURE

F

IGURE

F

4-10. I

4-1 1. S

NST ALLING KNURLED SCREWS

TRAIGHTENING PUMP TUBE

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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PERATI ON AND MAINTENANCE

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4.5 IR ZERO, SPAN CHECK

The infrared analyzer is subject to very little drift as long as a constant enclosure
temperature is maintained. A TOC zero and span check will identify the IR drift that may
occur since last calibration. For this reason, an IR zero and span check is required
periodically. Figures 4-12 through 4-17 illustrate the procedure for calibrating the IR
analyzer.

To Check IR Zero and Span, proceed as follows.

1. Locate zero and span gas canisters (customer supplied; available from Rosemount
Analytical, Inc.). Injection needles are taped inside canister caps.

2. Open the analyzer front door and locate the following controls on the control panel
(Figure 2-4 for location).

a. IR Ca libra te Switch - W hen t h is switch is in the " Norma l" po sitio n, re acto r gas f lo ws

through the IR detector and the digital display reads TOC concentration. When this
switch is in the "IR Calibrate" position, reactor gas bypasses the IR detector and
the digital display reads CO2 concentration directly.

b. CAL Gas Fitting - Calibration gas is injected through this fitting and enters the IR

detector directly.

c. IR "Span" and "Zero" - These screwdriver adjusted pots are accessible from the

front of the inner panel. The are used to adjust the M zero and span, respectively.

3. Set IR calibrate switch to "Calibrate" (Figure 4-12).

4. Attach injection needle to zero gas canister and insert into CAL gas fitting (Figure
4-13).

CAUTION: SHARP NEEDLE

Handle the injection needle with care.

5. Inject short bursts of zero gas and observe front panel display. Do not inject
continuously because 1) canister may be emptied or 2) the IR cell may be over­pressurized. When reading has stabilized, inject another burst of gas. Repeat until
reading remains stable.

6. Adjust IR ZERO until front panel display reads 000. Disregard the decimal point if
present (Figure

4-14).

30

Note
The zero adjust is very slow in responding. Make a slight adjustment and wait

for the reading to stabilize before making another adjustment. Continue until
display reads 000. The display will not register negative numbers in IR calibrate
mode.

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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IGURE

F

IGURE

F

4-12. S

4-13. I

ET SWITCH TO

NJECTING ZERO GAS

IR C

AL

IGURE

F

IGURE

F

4-15. I

4-16. A

NJECTING SPAN GAS

DJUSTING

PAN VALUE

IR S

IGURE

IGURE

F

7. Inject another burst of gas to ensure reading has not changed.

748263-E Rosemount Analytical March 2001

4-14. A

DJUSTING

IR ZERO

TO

000

F

Model 2100A Process Total Organic Carbon Analyzer

4-17. S

ET

IR S

WITCH TO

NORMAL

31

PERATI ON AND MAINTENANCE

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8. Using the span gas canister, repeat paragraphs 4 and 5 to calibrate span gas (Figure
4-15).

9. After reading has stabilized , adju st "IR Span " (Figure 4 -16) until digita l displa y registers
the same CO2 concentration shown on the gas canister (four digits for under 2000
PPM CO2, and three digits for concentrations over 2000 ppm). Ignore any decimal
point which may be present on the display. This decimal is only relevant for TOC
readout.

10. Set "IR Calibrate" switch back to "Normal" (Figure 4-17).

4.6 TOC ZERO, SPAN CHECK

TOC zero is affected by CO2 in the carrier gas, trace contaminants in the persulfate reagent
and IR drift. Normally, concentration of carrier gas CO2 is constant, reagent contaminants
are negligible and relatively constant, and IR drift is small. Therefore, unless the above
factors are known problems, TOC zero should drift very little and require only occasional
checks.

TOC span is affected by sample pump flow rate, carrier gas flow rate and IR span drift.
Normally, these factors are also stable. Therefore, TOC span need only be checked every 1
to 2 months.

Inject another burst of gas to ensure reading has not changed.
To check TOC zero and span, proceed as follows.

Note
Use the following procedure only. Do not use IR zero and span controls for TOC

zero and span.

1. Prepare TOC standard (See Section

5.1, STANDARDS PREPARATION).

2. Connect calibration standard to
"Standard" inlet. For maximum
accuracy, container should be
positioned so that liquid surface is
approximately at the same level as the
Sample Drain fitting on the side of the
Model 2100A. This will assure that the
liquid head at the pump inlet is the
same for both stream sample and
standard.

3. Turn off reagent pump (Figure 4-18).
This action turns off both the reagent

IGURE

F

4-18. R

EAGENT PUMP SWITCH

and sample pumps.

32

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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4. After analyzer reading is stable, adjust "TOC Zero" (Figure 4-19) until digital display
reads "000".

5. Rotate sample selector valve to "Standard" (Figure 4-20).

6. Turn on reagent pump (sample pump will also start) and wait for stable TOC reading
(Figure 4-21).

7. When analyzer reading is stable, adjust "TOC Span" (Figure 4-22) until digital display
reads the same TOC as the calibration standard. Analyzer is now calibrated.

8. Rotate sample selector valve to "Process Sample" (Figure 4-20). Analyzer is in normal
operation.

IGURE

F

IGURE

F

4-19. A

4-20. S

DJUSTING

AMPLE SELECTOR VALVE

TOC ZERO

IGURE

F

F

4-21. T

IGURE

URNING REAGENT PUMP

4-22. A

DJUSTING

ON

TOC SPAN

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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PERATI ON AND MAINTENANCE

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4.7 SEDIMENT REMOVAL

Sediment from the sample may collect in the bottom of the reactor over a period of time. To
remove this sediment while analyzer is operating, proceed as follows.

1. Turn off the UV lamp.

2. Remove rubber plug from reactor cap, and insert 1/8-inch O.D. Teflon tube to the
bottom of the reactor.

3. Use a syringe or siphon to draw the sediment from the bottom of the reactor (remove
as little reactor solution as possible). Refer to Section 4.10, paragraph 6.

4. Remove tube, and replace rubber plug.

5. When norm al reactor liquid level is re-estab lished, turn on the UV lamp and allow the
instrument to stabilize. The analyzer will be back to normal operation.

6. Close analyzer door.

7. Discard sediment in an approved chemical disposal container.

4.8 PUMP MOTOR BEARINGS

Pump motor bearings are sealed and do not require lubrication.

4.9 TOC ALARM

The TOC alarm may be adjusted at any point from 0 to 100% and above fullscale. (For
location, see Figure 3-1.)

To set this alarm point, proceed as follow s.

1. Press and ho ld ALARM SET SWITCH (S3). Alarm setpoint will now be displayed on
the front panel digital readout.

2. W hile still pressing S3, adjust ALARM SET potentiometer (R6) until desired setpoin t is
displayed on digital readout. Alarm is now adjusted.

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March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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4.10 PREPARATION FOR SHIPMENT

If the Model 2100A requires shipment or relocation, precautions must be taken to protect
the analyzer from the corrosive persulfate reagent. Employ the following procedure to drain
and flush the reactor vessel and tubing and prepare the instrument for movement:

Note
Please contact factory prior to shipment

CAUTION: GLASSWARE HAZARD

instrument to the factory.

of

This instrument utilizes numerous vessels and other components made of
glass. These components are fragile and should be handled carefully to avoid
breakage. During installation or maintenance, wear face shield or eye goggles,
gloves, and lab coat or long sleeved clothing. In the event of breakage,
immediately pick up and properly dispose of any large pieces. Use a suitable
wet/dry shop-type vacuum machine to remove fine pieces. See Mercury
Warning.

WARNING: MERCURY HAZARD

The ultraviolet light generating lamp contains mercury. Lamp breakage could
result in mercury exposure. Mercury is highly toxic if absorbed through the skin
or ingested, or if the vapors are inhaled.

Handle lamp assembly with extreme care.
If lamp is broken, avoid skin con. tact and inhalation in the area of the lamp or

the mercury spill.
Immediately clean up and dispose of the mercury spill and lamp residue as

follows:
Wearing rubber gloves and goggles, collect all droplets of mercury by means of

a suction pump and aspirator bottle with a long capillary tube. (Alternatively, a
commercially available mercury spill clean up kit, such as J.T. Baker product
No. 4439-01, is recommended.) Care. fully sweep any remaining mercury and
lamp debris into a dust pan. Carefully transfer all mercury, lamp residue and
debris into a plastic bottle which can be tightly capped. Label and return to
hazardous material reclamation center. Do not place in trash, incinerate or flush
down the sewer. Cover any fine droplets of mercury in non-accessible crevices
with calcium polysulfide and sulfur dust.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

35

PERATI ON AND MAINTENANCE

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1. Open the outer door of the analyzer and turn off the ultraviolet lamp. Reagent and
sample pumps remain running, and carrier and drying gases remain flowing.

2. Fill a clean container with clean, deionized or distilled water. Place reagent and
standard tubing into this container.

3. Switch the 3-way valve on the inner door from process sample position to standard
position.

4. Allow system to flush standard and reagent lines with clean water for 1/2 hour.

5. After this flushing period, remove the standard and reagent lines from the clean water
container. Allow liquid to drain for 15 minutes.

6. When standa rd and re agent lines run d ry, rem ove the rubber plug fro m the reac tor ca p
and drain the reactor. This can be done by either of the following procedures, with
1/8-inch O.D. Teflon tube and/or syringe.

• Insert the tube through the reactor cap to the bottom of the reactor. Use the syringe
to extract the liquid.

• Altern atively, immerse the tube into a container of clean water, filling the tube with
water. Plug one end of the tube with your finger, trapping the water inside, and
insert the opposite end through the reactor cap to the bottom of the reactor.
Position the opposing end of the tube lower than the reactor bottom, and allow the
siphoning process to remove all reactor liquids.

7. Using similar techniques as those in Step 6, fill the reactor with clean water. Ensure
that the filling container is positioned higher than the reactor when using the alternative
technique above. Continue filling the re actor until a cup of water flows from the waste
drain.

8. Repeat Step 6 to drain the reactor. Replace the rubber plug in the reactor cap.

9. Turn off the reagent and sample pumps.

10. Turn off the main power switch.

11. Discontinue the flow of carrier and drying gases. Disconnect the carrier and drying gas
lines at the bottom left side of the analyzer.

Note
External standard and reagent lines must not be cut or disconnected from

bottom left side fittings.

12. Coil and tie the standard and reagent lines, ensuring that no crimping or pinching
occurs.

36

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

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13. Discontinue flow through sample in connection. Disconnect sample in, sample drain,
and waste lines and vent fitting at the bottom left side of the analyzer. Partially insert
absorbent material (such as paper towels) into fittings.

14. Turn off power to analyzer at the circuit breaker and remove either the wiring to power
terminal strip on the inside rear (upper right) of enclosure or power cord from
receptacle.

15. Unplug the ultraviolet lamp from lamp power socket. Press latches on either side of
socket to release plug.

16. Remove lower end of the condenser tube from the reactor and fasten to the inner door
handle.

17. Remove the two springs that secure the reactor cap to the vessel.

18. Gently remove the reactor cap and ultraviolet lamp from the vessel. Application of a
little water to the seam between the two may loosen the fit.

19. Pack the reactor cap/lamp assembly in a suitable (preferably the original) shipping
container. Protection from shock and vibration is critical.

20. Insert absorbent material (such as paper towels) into the interior of the reactor vessel.
Leave all absorbent materials in place for shipment.

21. Wipe dry the interior of the analyzer. Secure the inner door. Attach shock absorbent
material (a sufficient amount to be squeezed between inner and outer doors) to the left
side of the inner door handle with tape. Secure the outer door.

22. Carefully remove the analyzer from its mountings, ensuring the standard and reagent
lines are not crimped.

23. Tilt instrument side-to-side and back-to-front to drain any remaining liquids from the
enclosure.

24. Pack the analyzer on its back in a suitable (preferably the original) shipping container
with sufficient packing material on all sides, top and bottom. Seal container properly.

25. Ship the ultraviolet lamp in its own container with, but not inside or attached to, the
Model

2100A

enclosure.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

37

PERATI ON AND MAINTENANCE

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4.11 CLEANING INFRARED ANALYZER OPTICAL UNIT

Introduction of dust or water into the infrared analyzer may cause drift. When adjustment of
the zero level with the zero control becomes impossible, check the IR analyzer for
contamination.

For maintenance of the IR analyzer,
refer to Figure 4-23 and do the
following:

1. Shut off reagent pump.

2. Stop the sample gas flow. Purge
the interior of the IR analyzer
with zero gas, if necessary.

3. Turn main power off.

4. Disconnect the IR analyzer tubes
from the optical unit.

5. Remove the two screws that
attach the IR analyzer optical unit
to the chassis, and remove the
unit.

6. Remove the two screws from the
IR Detector unit, and remove the
measuring cell and source unit
as an assembly.

7. If necessary, remove the two
screws from the source unit, and
disassemble the cell by cutting
the rubber sealant.

IGURE

F

4-23. I

NFRARED ANALYZER OPTICAL

U

NIT

XPLODED VIEW

– E

8. Clean both sides of the
measuring cell glass and the measuring cell interior with an ethanol-saturated cotton
swab.

CAUTION: GAS LEAK HAZARD

During disassembly and e-assembly of the IR measuring cell, avoid excess
pressure on the detector and infrared light source unit pipes. Deformation of
these pipes may cause a gas leak and malfunction of the analyzer. Proper use of
sealant is necessary to operate purge effectively and keep out unwanted CO2.

9. Reassemble by reversing instructions in paragraphs 1 through 7 above. Make sure to
replace the o-ring between the cell and detector, to clean off all rubber sealant and to
re-apply new sealant where removed.

38

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

PERATION AND MAINTENANCE

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4.12 CLEANING CONDENSATE TRAP

See Figure 4-24.

WARNING: HAZARDOUS AND CORROSIVE CHEMICALS

This instrument utilizes a user provided chemical reagent which is an aqueous
solution (14 to 40 %) o f either sodium persulfate, N a2S2O8, or ammonium persulfate,
(NH4)2S2O

The reagent solut ion and its co nstituent chemical s are stro ng oxidizing agent s and are
highly corrosive. They can cause severe skin burns and eye damage upon contact.
Ingestion could be fatal. Vapors can be very irritating to the skin, mucous membranes,
eyes and respiratory tract.

Reagent leakage can cause seve re corrosion damage to the instrument's enc losure
and/or components and could create an electrical shock hazard. The instrument
should be thoroughly checked for leaks during installation and start-up, routinely
thereafter, and any time the integrity of the reagent containment system is disrupted
(e.g., for tube or fitting replacement).

, acidified with con centrat ed phosph oric acid , H3PO4-

8

Chemical salt encrustation at joints or fittings is an early symptom of reagent leakage.
If evidence of leakage is discov­ered, the instrument should be
immediately shut down and the
leak repaired.

Refer reagent preparation, in­stallation and service to qualified
chemical technicians and observe
all precautions noted in the safety
messages located in appropriate
sections thro ughout this manu al.

Condensate Trap

1. Remove the drain hose, loosen and
remove the nuts on the tee fitting,
and detach the trap from the
instrument.

2. Unscrew the body of the
Condensate Trap. Clean all parts
with deionized water.

3. Reassemble and replace the trap.
Replace drain hose.

748263-E Rosemount Analytical March 2001

IGURE

F

4-24. C

Model 2100A Process Total Organic Carbon Analyzer

ONDENSATE TRAP ASSEMBLY

39

PERATI ON AND MAINTENANCE

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NOTES

40

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

P

REPARATION OF STANDARDS

5

5.1 STANDARDS PREPARATION

CAUTION: SAFETY PRECAUTIONS

Read this entire section before beginning to prepare standard solutions.
Observe standard laboratory safety precautions when performing the following

procedures.

To calibrate the readout and analog output of the Model 2100A, a standard sample of
known carbon content is required. Calibration should be checked every month or two. The
standard sample used for calibration should be somewhat representative of the carbon
material expected to be monitored. Carbon concentration should be close to, but slightly
less than the analyzer fullscale reading.

Fresh standards are required. Use reagent grade materials only.
All equipment and containers used for the carbon standard must be clean and free from

organic contaminants. Clean deionized or distilled water with carbon content less than five
percent of the intended concentration is required for the standard.

To prepare a standard sample from a pure solid material, use the following equations to
calculate the carbon concentration. Actual sample TOC will be the sum of this calculated
value plus background TOC (See Section 5.2, BACKGROUND TOC COMPENSATION).

(1) 1 ppm C = 1 mg C/liter solution

= 1,000 ppb

(2) TOC = mg/L C = (Wt)(n)(12)(1000)

(mw)(V)

(3) Wt/Liter of standard = (desired concentration in ppm C)(mw)

(12)(n)(1000)

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

41

REPARATION OF STANDARDS

P

As an alternative method to prepare a standard sample from a pure liquid material, use the
following equations.

(4) Vs = (desired concentration in ppm C)(mw) or

(12)(n)(1000)(d)

(5) mg/L C = (Vs)(d)(n)(12)(11000)

(mw)(V)

Where:

Wt = wei ght of compound in grams
mw = molecular weight of compound
n = number of carbon atoms per molecule
12 = atomic weight of carbon
V = volume of standard in liters
Vs = volume of pure liquid compound in ml
d = density of pure liquid compound in g/ml at room temperature

At the low concentrations sometimes encountered when using the Model 2100A, it may be
more convenient to prepare a concentrated standard, and then use a small measured
portion of this solution to prepare diluted standard solutions as required. The higher
concentration solution may be stored for some time if refrigerated in a dark brown bottle.
Adding 1 or 2 drops of phosphoric acid will also aid in preserving the standard.

42

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

REPARATION OF STANDARDS

P

5.2 BACKGROUND TOC COMPENSATION

All of the above calculations assume that the water used for preparing the standards is
pure, with no background TOC. This, of course, is never true. Therefore, in order to
determine the true carbon content of the calibration sample, it is necessary to determine
background carbon content. The background TOC may be determined by the following
procedure.

1. Calibrate the analyzer to the calculated calibration standard value, or if the analyzer
has been previously calibrated, simply run the analyzer on the calibration standard and
record the analyzer digital reading.

2. Introduce a sample of the "zero water" used for preparing the standard.

3. Record the digital reading.

4. Use the following equations to calculate the background.
TOC of the "zero water" used for preparing the standard and the true TOC of the

standard:
(6) TOC2 = (R2)(TOCC)

(RS – RZ)
(7) TOC = TOCC + TOC
Where:

TOC = True TOC

Z

TOC

= TOC of “zero water” = background TOC

TOCC= Calculated TOC from equation (1)

S

R
R

= Digital reading of standard

Z

= Digital reading of “zero” water

Z

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

43

REPARATION OF STANDARDS

P

Examples:
A. T o prepare a 1 liter 100 ppm standard of sucrose (cane sugar) in water (commonly

used for calibration in sugar plant or waste treatment plant applications), the
following calculations apply.

Sucrose (C12H22O11) has a molecular weight of 342.31 and has 12 carbon atoms
per molecule.

Therefore:

mw = 342.31
n = 12
Solving Equation (3):

Wt/L = (100)(342.31) = .23772 g

(12)(12)(1000)

0.23772 g of sucrose (easily weighed on a laboratory balance) dissolved in pure
water to a final volume of 1 liter will result in a standard of 100 ppm plus
background TOC.

B. To prepare a I liter 2 ppm standard of isopropanol (commonly used for

semiconductor industry applications), the following calculations apply.
Isopropanol (C3H7OH) has a molecular weight of 60.09, a density of .789 g/ml, and

3 carbon atoms per molecule.
Therefore:

mw = 60.09
d = .789
n = 3
Solving Equation (4):

Vs = (2)(60.09) = 0.004231 ml

(12)(3)(1000)(.789)

0.004231 ml is too small to measure with equipment normally found in laboratories.
If a 1000 ppm standard is prepared, 2.1154 ml of isopropanol would be required.
This is still not a convenient quantity to measure. However, 2 ml is easily measured
with a standard pipette. Solving Equation 5 for 2 ml in one liter:

44

mg/L C = (Vs)(d)(n)(12)(1000) = (2)(.789)(3)(12)(1000) = 945.4

(mw)(V) (60.09)(1)

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

REPARATION OF STANDARDS

P

Therefore, 2 ml of isopropanol dissolved in water to a final volume of 1 liter will
result in a standard of 945 ppm plus background TOC. When 2 ml of this solution is
diluted with water to make one liter of final calibration standard, the concentration
will be 1.89 ppm plus background TOC. 1.89 ppm is 94.5% of fullscale for a 0 to 2
ppm (0 to 2000 ppb) fullscale range, an ideal figure with which to work. Similarly, 5
ml of the 945 ppm solution in 1 L will be 4. 725 ppm or 94.5% of fullscale for a 0 to 5
ppm range.

C. To prepare a 1 liter 500 ppm standard of potassium hydrogen phathalate (KBP),

which is a commonly used standard for wastewater applications, the following

calculations apply.
KHP(C6H5O4K) has a molecular weight of 204.2 and 8 carbon atoms per molecule.
Therefore:

mw = 204.2
n = 8
Solving Equation (3):

wt/L = (500)(204.2) = 1.06354 g

(12)(8)(1000)

1.06354 g of KHP dissolved in pure water to a final volume of 1 liter will result in a
standard of 500 ppm plus background TOC. A 1000 ppm sample may be prepared
by doubling this amount of KHP.

D. To determine background TOC and true TOC of a sample, the following

calculations apply.
A 1000 ppb standard sample is prepared using one of the above methods. The

analyzer is calibrated to read 1000 ppb with this standard. When "zero water" is
introduced, the analyzer reads 58. To calculate the background TOC of the
sample:

S

R

= 1000
RZ = 58
TOCC = 1000

Using equation (6):
TOCZ = (RZ)(TOCC) = (58)(1000) = 61

(RS – RZ) (1000 – 58)
The true TOC of the sample is 1061 ppm. Calibrate analyzer to read 1061 with this

standard.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

45

REPARATION OF STANDARDS

P

NOTES

46

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

C

IRCUIT DESCRIPTIONS

6

6.1 GENERAL

This section describes how the IR detector signal is electronically processed. Refer to the
instrument schematic (See Appendix A) and to Figure 2-2 for component location.

6.2 INPUT SIGNAL CONDITIONER

The input signal from the NDIR detector is 10 to 110 mV DC. The two segments of amplifier
U1 provide necessary suppression and gain to produce an output signal of 0 to 10 V at test
point TP-6. Potentiometer R21 controls the suppression, and potentiometer R16 controls
the gain. R21 and R16 are factory set controls and normally require no further adjustment.

6.3 LINEARIZER

The output signal from the NDIR (and therefore, also from the signal conditioner) is
non-linear with respect to CO2 concentration. This non-linearity is corrected by generating a
non-linear gain of opposite magnitude. The correction signal is generated in three individual
straight segments and added together. At any given point, the product of the non-linear
input signal and non-linear gain produce a very close approximation to a linear output signal
at the output of the linearizer (pin 14, U2). Potentiometers R28, R30, R34, R38, R40 are fac­tory preset and should not be altered under any circumstances.

6.4 ZERO AND SPAN

A piggyback board is mounted on the main printed circuit board. This board contains a dual
amplifier and two user controls. A zero control (R8) allows null of the offset due to the
presence Of CO2 in the carrier gas. A span control (R7) allows the user to calibrate the
instrument against known standards. The output of the zero and span board at TP-1 is 0 to
10 V linear with CO2 concentration.

6.5 RECORDER OUTPUTS

The voltage at test point TP-1 is 0 to 10 V for a range of zero to fullscale TOC. Voltage
outputs are available at TB-3 of 0 to 1 V and 0 to 10 mV for this same range. In addition, a
socket is provided for the installation of an optional plug-in module for an isolated 4 to 20
mA signal. The outputs are individually adjustable to provide the 0 to 1 V and 0 to 10 mV
signals with digital readings as low as 0 to 500. R12 controls the 0 to 1 V output. R44

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

47

IRCUIT DESCRIPTIONS

C

controls the 0 to 10 mV and the 4 to 20 mA outputs simultaneously. Refer to Section 3.1,
paragraphs 22 through 24, for modul e adj ustments.

6.6 ALARM OUTPUT

A DPDT 10 A alarm control is provided as standard. The setpoint is continuously variable
over the range of 0 to 2500. The voltage developed at R6 "Alarm Setpoint" is buffered by
part of U3 and compared to the signal voltage by another part of U3. If the signal voltage is
higher than the set voltage, transistor Q1 and pilot relay K1 are energized. K1 in turn
energizes relay K2. Momentarily depressing pushbutton S3 displays the setpoint of the
alarm in ppm on the LCD display. Some hysteresis is built into the alarm circuit to prevent
relay chattering on the small amount of signal noise normally present. Thus the alarm
dropout point is somewhat lower than the alarm energize point.

6.7 DISPLAY

The display module is a 31/2-digit backlighted assembly. The range of the display is 0 to

1999. Provision has been made for adding a decimal point to the display (i.e. 199.9 etc.) by
soldering a jumper. This is accomplished by soldering a jumper to the appropriate pair of
holes in the D.P. column of the main PC board.

A jumper is provided on the piggyback board to allow 10 volts from the linearizer circuit to
read either 1999 for a 0 to .2% IR detector or 1000 for a 0 to 1% or 0 to 10% detector.

6.8 POWER SUPPLY

A power supply provides regulated ±15 VDC for the circuit board (Figures 2-6 and 2-7).
Factory-wired jumpers (A,B,C,D) select either 115 V or 230 V, 50/60 Hz operation.

A switch (SW 1) and 1 A fuse (Fl) are provided (See DRAWING 837484 in Appendix A). The
switch does not protect the contacts of relay K2. The rectified DC is regulated by separate
±15 V regulators so that the operation is independent of line voltage changes of 20%.

CAUTION: VOLTAGE CONVERSION

Changing jumpers alone is not enough to convert the instrument from 115 VAC
to 230 VAC or vice versa. Consult the factory for further information.

48

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

T

ROUBLESHOOTING

7

Should a malfunction occur in the Model 2100A TOC, the chart beginning on page 7-3 will
aid in determining and correcting the cause.

WARNING: ELECTRICAL SHOCK HAZARD

Servicing this instrument requires access to shock hazard level voltages which
can cause death or serious injury. Refer servicing to qualified personnel. Relay
contacts wired to separate power sources must be disconnected before
servicing.

WARNING: ULTRAVIOLET LIGHT HAZARD

Ultraviolet light from the reactor lamp can cause permanent eye damage. Do not
look directly at the ultraviolet source in the reactor for prolonged periods. Never
operate the lamp outside the reactor. Additionally, the lamp may break if fluid
flow is interrupted and then reintroduced to the hot lamp.

CAUTION: GLASSWARE HAZARD

This instrument utilizes numerous vessels and other components made of
glass. These components are fragile and should be handled carefully to avoid
breakage. During installation or maintenance, wear face shield or eye goggles,
gloves, and lab coat or long-sleeved clothing. In the event of breakage, im­mediately pick up and properly dispose of any large pieces. Use a suitable
wet/dry shop-type vacuum machine to remove fine pieces. Refer to Mercury
Warning on next page.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

49

ROUBLESHOOTING

T

WARNING: HAZARDOUS AND CORROSIVE CHEMICALS

This instrument utilizes a user provided chemical reagent which is an aqueous
solution (14 to 40%) of either sodium persulfate, Na2S208, or ammonium per­sulfate, (NH4)2S208, acidified with concentrated phosphoric acid, H3P04-

The reagent solution and its constituent chemicals are strong oxidizing agents
and are highly corrosive. They can cause severe skin burns and eye damage
upon contact. Ingestion could be fatal. Vapors can be very irritating to the skin,
mucous membranes, eyes and respiratory tract.

Reagent leakage can cause severe corrosion damage to the instrument's
enclosure and/or components and could create an electrical shock hazard. The
instrument should be thoroughly checked for leaks during installation and
start-up, routinely thereafter, and any time the integrity of the reagent contain­ment system is disrupted (e.g., for tube or fitting replacement).

Chemical salt encrustation at joints or fittings is an early symptom of reagent
leakage. If evidence of leakage is discovered, the instrument should be
immediately shut down and the leak repaired. Salt encrustation is normal at the
reactor top interface. Salt buildup must be removed periodically to avoid
collection on the case bottom, where the salt will damage the instrument
enclosure due to reaction with moisture.

Refer reagent preparation, installation and service to qualified chemical
technicians and observe all precautions noted in the safety messages located in
appropriate sections throughout this manual.

CAUTION: INSTRUMENT DAMAGE

Do not run pumps without carrier gas flow. Damage to the instrument can occur
if this requirement is not observed.

50

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

ROUBLESHOOTING

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WARNING: MERCURY HAZARD

The ultraviolet light generating lamp contains mercury. Lamp breakage could
result in mercury exposure. Mercury is highly toxic if absorbed through the skin
or ingested, or if the vapors are inhaled.

Handle lamp assembly with extreme care. If lamp if broken, avoid skin contact
and inhalation in the area of the lamp or the mercury spill.

]Immediately clean up and dispose of the mercury spill and lamp residue as
follows:

• Wearing rubber gloves and goggles, collect all droplets of mercury by

means of a suction pump and aspirator bottle with a long capillary tube.
(Alternatively, a commercially available mercury spill clean up kit, such
as J.T. Baker product No. 4439-01, is recommended.)

• Carefully sweep any remaining mercury and lamp debris into a dust

pan.

• Carefully transfer all mercury, lamp residue and debris into a plastic

bottle which can be tightly capped.

• Label and return to hazardous material reclamation center.

• Do not place in trash, incinerate or flush down sewer.

• Cover any fine droplets of mercury in non-accessible crevices with

calcium polysulfide and sulfur dust.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

51

ROUBLESHOOTING

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SYMPTOM POSSIBLE CAUSE CORRECTION

Digital display dark. No power.

Analog output zero. No power.

UV lamp out. No power.

High sample TOC.

Low carrier flow.

High TOC reading.

Plugged gas restrictor.

Check to see that power is
turned on.

Check PC Board power
switch (left position).

Check fuse; replace if
necessary.

Confirm analyzer calibr ati on
with calibration standard.
Analyzer grab sample with
lab TOC analyzer.
Recalibrate if necessary.

Check gas supply pressure
and carrier gas pressure
setting. Adjust setting and
recalibrate analyzer if
necessary. Also, see "Low
or no gas through reactor"
below.

Replace restrictor (located
on the carrier regulator).

Low TOC reading.

No sparger air.

Inadequate amount of
phosphoric acid in reagent

Low sample TOC.

Carrier gas flow too high.

Check all gas flows.
Replace sparger gas
restrictor located on the
carrier regulator if corroded
or plugged. WARNING: DO

NOT OPERATE PUMPS
WITH GAS OFF.

Confirm that acid was added
(See Section 4). Increase
amount if too low.

Check analyzer with
calibration standard. Take
grab sample for lab
analysis.

Check carrier gas pressure
setting. Adjust and
recalibrate if necessary.

52

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

SYMPTOM POSSIBLE CAUSE CORRECTION

Check analyzer with

Analyzer out of calibration.

calibration standard.
Recalibrate if necessary.

ROUBLESHOOTING

T

Zero or near zero TOC
reading on calibration
standard.

Out of reagent.

Check reagent container
and refill if necessary.

Check reagent mixing

Reagent improperly mixed.

procedure to be sure
reagent has been mixed to
proper concentrations.

Weak UV lamp (not likely). Replace lamp.

Check that transformer is

Lamp not burning.

plugged in, lamp is plugged

in and lamp switch is ON.
Lamp burned out. Replace lamp.
Sample pump turned off. Turn on pump.
Reagent pump turned off. Turn on pump.
Sample pump not pumping. Repl ace pu mp tub e.
Reagent pump not pumping. Replace pump tub e.

Flush out lines to remove

plug, and be sure proper

reagent is being used. DO
Reagent pump or reagent
tubing plugged.

NOT SUBSTITUTE

POTASSIUM

PERSULFATE FOR

SODIUM PERSULFATE.

Replace pump tube.

Leak in reagent pump inlet
causing loss of prime.

Defective reagent pump
motor or sample pump
motor.

748263-E Rosemount Analytical March 2001

Place two nylon Ty-Raps

around each end of the

pump tubing to assure tight

seal.

Replace motor.

Model 2100A Process Total Organic Carbon Analyzer

53

ROUBLESHOOTING

T

SYMPTOM POSSIBLE CAUSE CORRECTION

Check infrared analyzer with
Infrared analyzer defective
or out of calibration.

calibration gases. Replace

or service infrared analyzer

if necessary.

Replace reagent if dirty. Mix

reagent thoroughly until all

crystals are dissolved.

ENSURE POTASSIUM

PERSULFATE HAS NOT

BEEN SUBSTITUTED FOR

SODIUM PERSULFATE,

Short reagent pump tube
life.

Dirt or crystals in reagent
solution.

OR POTASSIUM OR

SODIUM SULFATE FOR

AMMONIUM

PERSULFATE.

Corroded pump rollers. Replace roller assembly.

Negative TOC reading. Analyzer out of calibration.
Analyzer reading does not

change when sample is
changed or sample pump is

“IR Calibrate” switch is in
“Calibrate” position.

turned on or off.

Excessive back pressure in
system is blowing gas out
reactor overflow.

After period of normal
operation, analyzer reading
does not change when
sample is changed or
sample pump is turned on or

Water in lines to or from IR
detector.

off.

Recalibrate (See Section

4.4).

Switch to “Normal”.

Check sample flow lines for

blocked components (valve,

solenoid valve, and

condensate trap).

Remove water and correct

cause. Check IR cell for

water and clean cell if water

is found.

Check to confirm that

analyzer is correctly vented

(See Section 2.4.2.6) and

correct if necessary.

54

Gas leaks.

Check all fittings and tighten

where necessary

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

SYMPTOM POSSIBLE CAUSE CORRECTION

ROUBLESHOOTING

T

Water in vent lines, either
internal or external.

Sparger gas/liquid separator
flooded.

Excessive noise on display
and analog output only wi th
"IR Calibrate" switch in
"Normal" position only.

Excessive noise on digital
display and on analog
output only with "IR
Calibrate" switch in either
position.

Improper drain and/or vent
installation.

Improper drain and/or vent
installation.

Correct installation (VERY
IMPORTANT). See Section

2.4.2.
Correct installation (VERY

IMPORTANT). See Section

2.4.2.

Remove source of back
Water or other source of
back pressure in vent line.

pressure. Check that all

external vent lines slope

downward (Section 2.4.2.6)
Condensate trap blocked.

Clean condensate trap per

Section 4.12.
Water or dirt in IR cell. Clean or replace cell.
Defective IR analyzer. Replace IR analyzer.

Loose connection.

Check wiring and tighten

connections if necessary.
Defective electronics board. Replace electronics board.

Digital display has reading
but analog signal incorrect
or not present.

No output from 4 to 20 mA
terminals (test meter must
be in series with 4 to 20 mA
loop).

4 to 20 mA output always
reads 4 mA with positive
readout on the digital
display (test meter must be
in series with 4 to 20 mA
loop).

R12 or R44 not adjusted. Adjust pot.

4 to 20 mA plug-in option
not installed or not plugged

Install 4 to 20 mA option.
in.

Defective 4 to 20 mA
module.

4 to 20 mA plug-in
misadjusted.

R44 not adju sted or span
pot on 4 to 20 mA plug-in
option not adjusted.

Defective 4 to 20 mA
module.

Replace plug-in module.

Calibrate 4 to 20 mA

module. (See Section 3.1,

steps 22 to 24.)

Check and adjust R44 first if

necessary. If output still

reads 4 mA, then adjust pot

on plug-in module.

Replace plug-in module.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

55

ROUBLESHOOTING

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SYMPTOM POSSIBLE CAUSE CORRECTION

Check carrier gas source

Low carrier gas pressure.

pressure and correct if
necessary.

Low or no gas flow through
reactor.

Saw-tooth recorder pattern.

Incorrect carrier gas
pressure setting.

Adjust to correct setting and
recalibrate analyzer .

Replace restrictor.
Plugged carrier gas
restrictor.

WARNING: DO NOT

OPERATE PUMPS WITH

GAS OFF.

Leaking fitting. Tighten all fittings.
Plugged sparging frit in

reactor.

Clean reactor with acid.

Replace check valve.
Plugged carrier gas check
valve.

WARNING: DO NOT

OPERATE PUMPS WITH

GAS OFF.

Varying carrier pressure.
Instrument carrier gas

supply pressure too low.
Defective carrier pressure

regulator.

Install pressure regulator in

supply line to instrument.

Raise carrier supply

pressure.

Replace regulator.

Dryer turning brown or
purple.

Infrared analyzer does not
respond to calibration
gases.

56

Liquid trapped in drain or
vent line.

Remove liquid and correct

installation.
Normal condition. No corrective action req’d.
Empty canisters. Replace canisters.

Loose tube or fitting in IR
analyzer.

Tighten or replace fitting or

tubing.

Carefully clean cell windows
Dirty IR cell windows.

with soft cotton swab and

ethanol. (See Section 4.11.)
Defective IR analyzer.

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

Repair or replace IR

analyzer.

SYMPTOM POSSIBLE CAUSE CORRECTION

ROUBLESHOOTING

T

IR reading too low when
span gas introduced, and IR
span pot at maximum
setting.

IR cell windows require
frequent cleaning, cell is
corroding, smell of chlorine
observed at instrument vent.

Analog output normal, but
no digital readout or digital
readout always reads zero.

UV lamps and pumps
operate, but no analog
output present and digital
display is dark.

"IR Calibrate" switch in
“Normal” position.

Switch to "Calibrate" during
IR calibration.

Any of above. See above.

High salt concentration in
sample.

Contact factory for solutions.

Defective display module. Repair or replace module.
Defective ribbon cable. Replace cable.

Defective electronics board.

Blown or defective fuse on
electronics board.

Power switch on, electronics
board turned off.

Repair or replace
electronics board.

Replace fuse on electronics
board located at top of
analyzer.

Turn on switch (left
position).

Analyzer reading seems to
drift with ambient
temperature changes.

Zero drifts with sample
pump off and air carrier
flowing.

Sample TOC may be
changing with ambient
temperature.

Instrument temperature
controller set too low.

Defective instrument
enclosure temperature
control system

Air compressor inlet located
too close to source of CO2
or inside building occupied
by people.

Instrument air dryer removing
varying amounts of CO2.

Confirm analyz er zero and
calibration.

Install thermometer and
adjust temperature control
for 130°F.

Locate and replace
defective component.

Move compressor inlet or
switch to nitrogen carrier
gas. Recalibrate analyzer.

Switch to more stable carrier
gas.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

57

ROUBLESHOOTING

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SYMPTOM POSSIBLE CAUSE CORRECTION

Corrosion of IR detector and
Tygon tubing.

Air being used as carrier
gas. UV lamp oxidizes
oxygen to ozone, a
corrosive agent.

Use CO2-free nitrogen as

carrier gas. DO NOT USE

AIR OR OXYGEN AS

CARRIER GAS.

58

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

R

EPLACEMENT PARTS

8

WARNING: PARTS INTEGRITY

Tampering with or unauthorized ubstitution of components may adversely affect
safety of this product. Use only factory-approved components for repair.

8.1 RECOMMENDED SPARE PARTS

Qty

2 010963
2 010964
2 010965
2 010966
2 030504
2 030505
1 070627 Gasket Sleeve, Reactor, Teflon
1 090092 Restrictor, 400 cc, Green
1 090093 Restrictor, 20 cc, Union
1 090094 Restrictor, 50 cc, White
1 090095 Restrictor, Male Connector, 100 cc, Blue
1 090096
1 090868
1 512092 Lamp, Ultraviolet
1 512096 Reactor Cap
1 512097 Reactor Body
1 517798 Septa, Pierced (pkg. of 10)
1 517803 Septa (pkg. of 10)
1 523341 Tubing, 1/8-inch Teflon, 5 feet
2 837353
2 837354
2 837356
1 902515 Check Valve

Part

Number

Description

5

Gas, Zero

5

Gas, Span, 2 to 50 ppm ranges (1,770 ppm CO2 in N2)

5

Gas, Span, 100 to 1,000 ppm ranges (9,020 ppm CO2 in N2)

5

Gas, Span, 2,000 to 5,000 ppm ranges

5

Persulfate, Sodium, 500 g

5

Persulfate, Ammonium, 500 g

5

Restrictor, Male Connector, 200 cc, Blue

5

Filter, Infrared Analyzer, In-line

5

Pump Tube, Norprene 7013, ranges 500 to 5,000 ppm

5

Pump Tube, Norprene 7014, ranges 20 to 200 ppm

5

Pump Tube, Norprene 7016, ranges 2 to 10 ppm

5

Specify analyzer range when ordering.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

59

EPLACEMENT PARTS

R

8.2 REPLACEMENT PARTS (NUMERICALLY)

Part Number Description

010115 Switch, Rocker
010116 Switch, Rocker (Infrared Analyzer)
010443
010963
010964
010965
010966
030504
030505
070627 Gasket Sleeve, Reactor, Teflon
080014 Container, Reagent, 20 L
080046 Key, Enclosure
080874 Valve, 3-Way, Stainless Steel
080950 Cross, Teflon
090092 Restrictor, 400 cc, Green
090093 Restrictor, 20 cc, Union
090094 Restrictor, 50 cc, White
090095 Restrictor, Male Connector, 100 cc, Blue
090096 Restrictor, Male Connector, 200 cc, Blue
090828 Filter, Collins
090864
090865
090866
090868 Filter, Infrared Analyzer, In-line
152106 Tubing, 1/8-inch O.D.
512092 Lamp, Ultraviolet
512096 Reactor Cap
512097 Reactor Body
517322 Septa, Gas Injector (pkg. of 10)
517798 Septa, Pierced (pkg. of 10)
517803 Septa (pkg. of 10)
523341 Tubing, 1/8-inch Teflon, 5 feet
523893 Fuse, 5 amp (pkg. of 5)
644790 Trap Assembly, TOCA Condensate
655374 Tee, Modified 1/4 T x 1/4 MPT Cres.
748263 Manual, Instruction
837120 Display, Back-lighted (LCD)
837326 Cable, Ribbon (14 Lead)
837353

6
5
5
5
5
5
5

5
5
5

5

Transformer, Step-Down
Gas, Zero
Gas, Span, 2 to 50 ppm ranges (1,770 ppm CO2 in N2)
Gas, Span, 100 to 1,000 ppm ranges (9,020 ppm CO2 in N2)
Gas, Span, 2,000 to 5,000 ppm ranges
Persulfate, Sodium, 500 g
Persulfate, Ammonium, 500 g

Pump Head, 7013
Pump Head, 7014
Pump Head, 7016

Pump Tube, Norprene 7013, ranges 500 to 5,000 ppm

6

Applicable to instruments with serial numbers less than 1000083.

60

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

EPLACEMENT PARTS

R

837354
837356

5
5

Pump Tube, Norprene 7014, ranges 20 to 200 ppm

Pump Tube, Norprene 7016, ranges 2 to 10 ppm
837404 Temperature Controller 230 V
837405 Thermistor Assembly
837406 Transformer Assembly, Ultraviolet, 230 V
837407 Printed Circuit Board Assembly, Model 2100A, 115 V
837409 Heater Assembly, 230 V
837411 Cable, 115 V Harness
837414 Transformer Assembly, Ultraviolet, 115 V
837415 Temperature Controller 115 V
837417 Heater Assembly, 115 V
837418 Fan Assembly, 115 V
837419 Fan Assembly, 230 V
837435 Cable, 230 V Harness
837436 Cable, Signal Assembly
837443 Regulator Assembly
837444 Solenoid Assembly, 115 V DC
837445 230V Board Assembly, Model 2100A
837465 Elbow, Waste
837467 Connector, Male 1/8" Modified
837519 Z Purge Kit, Class 1, Division 2, Groups C and D
837555 Current Output, 4 to 20 mA
837564 Motor, 18 rpm, 120 V, 50/60 Hz, Sample Pump
837565 Motor, 7 rpm, 115 V, 50/60 Hz, Sample Pump
837566 Motor, 15 rpm, 230 V, 50/60 Hz, Sample Pump
837567 Motor, 6 rpm, 230 V, 50/60 Hz, Reagent Pump
884873 Filter, Air 25 cfm, 1/8 NPT
899322 Indicator Light, LED, Red
899486 Shipping Kit
901842 Latch, Flush - Lift & Turn
901844 Fastener, Stud, 1/4-Turn, Quick-Release
901845 Fastener, Receptacle, 1/4-Turn, Quick-Release
901961

7

Transformer, Step-Down
902515 Valve, Check

7

Applicable to instruments with serial numbers greater than 1000082.

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

61

EPLACEMENT PARTS

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8.3 REPLACEMENT PARTS (ALPHABETICALLY)

Part Number Description

837411 Cable, 115 V Harness
837435 Cable, 230 V Harness
837326 Cable, Ribbon (14 Lead)
837436 Cable, Signal Assembly
837467 Connector, Male 1/8" Modified
080014 Container, Reagent, 20 L
080950 Cross, Teflon
837555 Current Output, 4 to 20 mA
837120 Display, Back-lighted (LCD)
837465 Elbow, Waste
837418 Fan Assembly, 115 V
837419 Fan Assembly, 230 V
901845 Fastener, Receptacle, 1/4-Turn, Quick-Release
901844 Fastener, Stud, 1/4-Turn, Quick-Release
884873 Filter, Air 25 cfm, 1/8 NPT
090828 Filter, Collins
090868 Filter, Infrared Analyzer, In-line
523893 Fuse, 5 amp (pkg. of 5)
010965
010964
010966
010963
070627 Gasket Sleeve, Reactor, Teflon
837417 Heater Assembly, 115 V
837409 Heater Assembly, 230 V
899322 Indicator Light, LED, Red
080046 Key, Enclosure
512092 Lamp, Ultraviolet
901842 Latch, Flush - Lift & Turn
748263 Manual, Instruction
837566 Motor, 15 rpm, 230 V, 50/60 Hz, Sample Pump
837564 Motor, 18 rpm, 120 V, 50/60 Hz, Sample Pump
837567 Motor, 6 rpm, 230 V, 50/60 Hz, Reagent Pump
837565 Motor, 7 rpm, 115 V, 50/60 Hz, Sample Pump
030505
030504
837407 Printed Circuit Board Assembly, Model 2100A, 115 V
837445 Printed Circuit Board Assembly, Model 2100A, 230 V
090864
090865

5
5
5
5

5
5

5
5

Gas, Span, 100 to 1,000 ppm ranges (9,020 ppm CO2 in N2)
Gas, Span, 2 to 50 ppm ranges (1,770 ppm CO2 in N2)
Gas, Span, 2,000 to 5,000 ppm ranges
Gas, Zero

Persulfate, Ammonium, 500 g
Persulfate, Sodium, 500 g

Pump Head, 7013
Pump Head, 7014

62

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer

EPLACEMENT PARTS

R

Part Number Description

090866
837353
837354
837356

5
5
5
5

Pump Head, 7016

Pump Tube, Norprene 7013, ranges 500 to 5,000 ppm

Pump Tube, Norprene 7014, ranges 20 to 200 ppm

Pump Tube, Norprene 7016, ranges 2 to 10 ppm
512097 Reactor Body
512096 Reactor Cap
837443 Regulator Assembly
090093 Restrictor, 20 cc, Union
090092 Restrictor, 400 cc, Green
090094 Restrictor, 50 cc, White
090095 Restrictor, Male Connector, 100 cc, Blue
090096 Restrictor, Male Connector, 200 cc, Blue
517803 Septa (pkg. of 10)
517322 Septa, Gas Injector (pkg. of 10)
517798 Septa, Pierced (pkg. of 10)
899486 Shipping Kit
837444 Solenoid Assembly, 115 V DC
010115 Switch, Rocker
010116 Switch, Rocker (Infrared Analyzer)
655374 Tee, Modified 1/4 T x 1/4 MPT Cres.
837415 Temperature Controller 115 V
837404 Temperature Controller 230 V
837405 Thermistor Assembly
837414 Transformer Assembly, Ultraviolet, 115 V
837406 Transformer Assembly, Ultraviolet, 230 V
010443
901961

6
7

Transformer, Step-Down

Transformer, Step-Down
644790 Trap Assembly, TOCA Condensate
152106 Tubing, 1/8-inch O.D.
523341 Tubing, 1/8-inch Teflon, 5 feet
080874 Valve, 3-Way, Stainless Steel
902515 Valve, Check
837519 Z Purge Kit, Class 1, Division 2, Groups C and D

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

63

EPLACEMENT PARTS

R

NOTES

64

March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer