Rosemount 2100A Process Total Organic Carbon TOC Analyzer-Rev E Owner's manual

Brand: Rosemount

Model: 2100A Process Total Organic Carbon TOC Analyzer-Rev E

Type: Owner's manual

Rosemount Analytical

ODEL

2100A

ROCESS

OTAL

RGANIC

ARBON

NALYZER

NSTRUCTION

ANUAL

748263-E

OTICE

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

Manual Part Number 748263-E

March 2001

Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

Teflon

is a registered trademark of E.I. duPont de Nemours and Co., Inc.

Norprene

is a registered trademark of Saint-Gobain Performance Plastics

Tygon

is a registered trademark of Saint-Gobain Performance Plastics

SNOOP

is a registered trademark of NUPRO Co.

Ty-Rap

is a registered trademark of Thomas & Betts Corp.

Caplugs

is a registered trademark of Caplugs

ONTENTS

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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

ECTION

1. I

NTRODUCTION

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

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

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

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

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

ONTENTS

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

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

ONTENTS

748263-E Rosemount Analytical March 2001

iii

Model 2100A Process Total Organic Carbon Analyzer

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

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

ONTENTS

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

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

ABLES

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

ONTENTS

748263-E Rosemount Analytical March 2001

Model 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

REFACE

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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.

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.

WARNING: ELECTRICAL SHOCK HAZARD

REFACE

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

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.

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.

Tampering or unauthorized substitution of components may adversely affect

safety of this product. Use only factory documented components for repair.

CAUTION: PARTS INTEGRITY

WARNING: HIGH PRESSURE GAS CYLINDERS

WARNING: POSSIBLE EXPLOSION HAZARD

REFACE

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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.

WARNING: MERCURY HAZARD

REFACE

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

PECIFICATIONS

- O

PERATIONAL

PRINCIPLE

Ultraviolet/persulfate oxidation to CO2

ETECTION

ETHOD

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

EPRODUCIBILITY

±2% fullscale

ESPONSE

IME

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

SPECIFICATIONS - SAMPLE REQUIREMENTS

LOW

ATE

AMPLE

NLET

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

LOW

ATE

IDE

TREAM

1.1 to 15 ml/min. depending on reactor range

NLET

RESSURE

Constant 2 psig minimum, 15 psig maximum at sample inlet

EMPERATURE

35°F to 160°F (2°C to 71°C)

USPENDED

OLIDS

Sample must be free of particles larger than 100 microns

HLORIDES

Up to 1000 ppm (wt)

±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.

REFACE

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

PECIFICATIONS

- A

MBIENT

EQUIREMENTS

TEMPERATURE

35°F to 122°F (2°C to 50°C)

Protect from heating effect of direct sunlight

UMIDITY

0 to 90% relative humidity

PECIFICATIONS

- D

ATA

UTPUT

OCAL

EADOUT

Electroluminescent backlighted liquid crystal display (LCD) reading of organics

in ppm (carbon)

NALOG

UTPUT

– S

TANDARD

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

NALOG

UTPUT

– O

PTIONAL

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

LARM

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

contacts

SPECIFICATIONS - UTILITY REQUIREMENTS

OWER

– S

TANDARD

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

OWER

– O

PTIONAL

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

ARRIER

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

RAIN

Open atmospheric: 1/2-inch minimum inner diameter

2 L/min. maximum, 1/2-inch NPT

ENT

Atmospheric operation only.

1 L/min. maximum 1/2-inch NPT gas flow

Connection normally not required

EAGENT

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

REFACE

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

PECIFICATIONS

- P

HYSICAL

ELECTRICAL CLASSIFICATION – STANDARD

General purpose (non-hazardous locations)

LECTRICAL

LASSIFICATION

– O

PTIONAL

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

ENCLOSURE

NEMA-3R

IMENSIONS

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

EIGHT

(115 VAC) 60 lb. (27.2 kg)

(230 VAC) 65 lb. (29.5 kg)

HIPPING

EIGHT

(115 VAC) 75 lb. (34 kg)

(230 VAC) 80 lb. (36.3 kg)

SPECIFICATIONS - OPTIONAL TYPE Z PURGE

URGE

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

PERATING

RESSURE

.2 inch H

NLET

RESSURE

Constant 2 psig minimum, 15 psig maximum at sample inlet

EMPERATURE

35°F to 160°F (2°C to 71°C)

USPENDED

OLIDS

Sample must be free of particles larger than 100 microns

HLORIDES

Up to 1000 ppm (wt)

REFACE

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

USTOMER

ERVICE

, T

ECHNICAL

SSISTANCE AND

IELD

ERVICE

For order administration, replacement Parts, application assistance, on-site or factory

repair, service or maintenance contract information, contact:

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 sender, freight collect.

When returning any product or component that has been exposed to a toxic, corrosive

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

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 Department at:

Rosemount Analytical Inc.

Phone: 1-714-986-7600

FAX: 1-714-577-8006

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)

NTRODUCTION

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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 CO

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

LANTS

Reclaimed water

Deionized water plant input

HEMICAL

ETROCHEMICAL

LANTS

Cooling water

Waste water

Organic loading of process streams

Product loss monitoring

OOD

EVERAGE

LANTS

Cooling water

Waste water

Condensate return

Ion exchange effluent

Rinse water

OWER

LANTS

Cooling water

Boiler feedwater

Condensate return

Waste water

ATER

ASTEWATER

LANTS

Raw and finished water quality

Potable water

Effluent water

NTRODUCTION

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

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 CO

, as shown in the following equation:

Organics + [S

]

-2

+ H

½ CO

+ [SO

]

-2

+ H

The concentration Of CO

is then determined with an infrared analyzer. If dissolved CO

and inorganic carbon are removed prior to oxidation, then the CO

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 CO

. This

acidified solution is then sparged with carrier gas (nitrogen) to remove the CO

and is

passed through a liquid/gas separator to vent the CO

. 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 CO

The CO

-containing carrier gas is passed through a condensate trap to remove moisture,

and then through a non-dispersive infrared analyzer which measures the CO

concentration.

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.

NTRODUCTION

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

IGURE

1-1. S

IMPLIFIED

ODEL

2100A F

LOW

IAGRAM

(TOC V

ERSION

)

IGURE

1-2. S

IMPLIFIED

ODEL

2100A F

LOW

IAGRAM

(TC V

ERSION

)

NTRODUCTION

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

NOTES

NSTALLATION

748263-E Rosemount Analytical March 2001

Model 2100A Process Total Organic Carbon Analyzer

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.

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Rosemount 2100A Process Total Organic Carbon TOC Analyzer-Rev E Owner's manual

Rosemount 2100A Process Total Organic Carbon TOC Analyzer-Rev E Owner's manual

Rosemount 2100A Process Total Organic Carbon TOC Analyzer-Rev E Owner's manual

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