Rosemount Analytical
M
ODEL
2100A
P
ROCESS
T
OTAL
O
RGANIC
C
ARBON
A
NALYZER
I
NSTRUCTION
M
ANUAL
748263-E
N
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
C
ONTENTS
748263-E Rosemount Analytical March 2001
i
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
S
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
C
ONTENTS
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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
C
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
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
C
ONTENTS
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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
T
ABLES
4-1. Application Data......................................................................................... 25
C
ONTENTS
748263-E Rosemount Analytical March 2001
v
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
P
REFACE
748263-E Rosemount Analytical March 2001
P1
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
P
REFACE
P2
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
P
REFACE
748263-E Rosemount Analytical March 2001
P3
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
P
REFACE
P4
March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer
S
PECIFICATIONS
- O
PERATIONAL
PRINCIPLE
Ultraviolet/persulfate oxidation to CO2
D
ETECTION
M
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
R
EPRODUCIBILITY
±2% fullscale
1
R
ESPONSE
T
IME
Less than 5 minutes for 90% of fullscale for most ranges
SPECIFICATIONS - SAMPLE REQUIREMENTS
F
LOW
R
ATE
S
AMPLE
I
NLET
50 to 2000 ml/min. depending on sample availability and response required
F
LOW
R
ATE
S
IDE
S
TREAM
1.1 to 15 ml/min. depending on reactor range
I
NLET
P
RESSURE
Constant 2 psig minimum, 15 psig maximum at sample inlet
T
EMPERATURE
35°F to 160°F (2°C to 71°C)
S
USPENDED
S
OLIDS
Sample must be free of particles larger than 100 microns
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.
P
REFACE
748263-E Rosemount Analytical March 2001
P5
Model 2100A Process Total Organic Carbon Analyzer
S
PECIFICATIONS
- A
MBIENT
R
EQUIREMENTS
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
- D
ATA
O
UTPUT
L
OCAL
R
EADOUT
Electroluminescent backlighted liquid crystal display (LCD) reading of organics
in ppm (carbon)
A
NALOG
O
UTPUT
– S
TANDARD
Voltage Output: 0 to 1 VDC; 0 to 10 mV DC
A
NALOG
O
UTPUT
– O
PTIONAL
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
SPECIFICATIONS - UTILITY REQUIREMENTS
P
OWER
– S
TANDARD
115 VAC ±10%, 50/60 Hz, 1 phase, 3 amps, 350 watts
P
OWER
– O
PTIONAL
230 VAC ±10%, 50/60 Hz, 1 phase, 1.5 amps, 350 watts
C
ARRIER
G
AS
200 to 500 scc/min. nitrogen, 1/8-inch tubing (see Table 4-1 for pressure)
D
RAIN
Open atmospheric: 1/2-inch minimum inner diameter
2 L/min. maximum, 1/2-inch NPT
V
ENT
Atmospheric operation only.
1 L/min. maximum 1/2-inch NPT gas flow
Connection normally not required
R
EAGENT
19 L/mo. (all ranges except 0-5000 ppm) to 47 L/mo. (0 to 5000 ppm)
P
REFACE
P6
March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer
S
PECIFICATIONS
- P
HYSICAL
ELECTRICAL CLASSIFICATION – STANDARD
General purpose (non-hazardous locations)
E
LECTRICAL
C
LASSIFICATION
– 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
W
EIGHT
(115 VAC) 75 lb. (34 kg)
(230 VAC) 80 lb. (36.3 kg)
SPECIFICATIONS - OPTIONAL TYPE Z PURGE
P
URGE
G
AS
Inert gas, such as nitrogen, supplied through 1/8-inch tubing at 20 psig
O
PERATING
P
RESSURE
.2 inch H
2
O
I
NLET
P
RESSURE
Constant 2 psig minimum, 15 psig maximum at sample inlet
T
EMPERATURE
35°F to 160°F (2°C to 71°C)
S
USPENDED
S
OLIDS
Sample must be free of particles larger than 100 microns
C
HLORIDES
Up to 1000 ppm (wt)
P
REFACE
748263-E Rosemount Analytical March 2001
P7
Model 2100A Process Total Organic Carbon Analyzer
C
USTOMER
S
ERVICE
, T
ECHNICAL
A
SSISTANCE AND
F
IELD
S
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
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 Department at:
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
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)
1
I
NTRODUCTION
748263-E Rosemount Analytical March 2001
1
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
2
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
S
EMICONDUCTOR
P
LANTS
Reclaimed water
Deionized water plant input
C
HEMICAL
/P
ETROCHEMICAL
P
LANTS
Cooling water
Waste water
Organic loading of process streams
Product loss monitoring
F
OOD
/B
EVERAGE
P
LANTS
Cooling water
Waste water
Condensate return
Ion exchange effluent
Rinse water
P
OWER
P
LANTS
Cooling water
Boiler feedwater
Condensate return
Waste water
W
ATER
/W
ASTEWATER
P
LANTS
Raw and finished water quality
Potable water
Effluent water
I
NTRODUCTION
2
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
2
, as shown in the following equation:
Organics + [S
2
O
8
]
-2
+ H
2
O
½ CO
2
+ [SO
4
]
-2
+ H
2
SO
4
The concentration Of CO
2
is then determined with an infrared analyzer. If dissolved CO
2
and inorganic carbon are removed prior to oxidation, then the CO
2
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
2
. This
acidified solution is then sparged with carrier gas (nitrogen) to remove the CO
2
and is
passed through a liquid/gas separator to vent the CO
2
. 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
2
.
The CO
2
-containing carrier gas is passed through a condensate trap to remove moisture,
and then through a non-dispersive infrared analyzer which measures the CO
2
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.
UV
I
NTRODUCTION
748263-E Rosemount Analytical March 2001
3
Model 2100A Process Total Organic Carbon Analyzer
F
IGURE
1-1. S
IMPLIFIED
M
ODEL
2100A F
LOW
D
IAGRAM
(TOC V
ERSION
)
F
IGURE
1-2. S
IMPLIFIED
M
ODEL
2100A F
LOW
D
IAGRAM
(TC V
ERSION
)
I
NTRODUCTION
4
March 2001 Rosemount Analytical 748263-EModel 2100A Process Total Organic Carbon Analyzer
NOTES
2
I
NSTALLATION
748263-E Rosemount Analytical March 2001
5
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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