Endres+Hauser TOCII CA72TOC Operating instructions

BA448C/07/en/11.09

71098200

Operating Instructions

TOCII CA72TOC

Analyzer for online determination of TOC in aqueous media

using thermic catalytic combustion

Endress+Hauser

TOCII CA72TOC

Endress+Hauser 3

Table of contents

1 Safety instructions . . . . . . . . . . . . . . . . 5

1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Installation, commissioning and operation . . . . . . . . 5

1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.5 Notes on safety icons and symbols . . . . . . . . . . . . . . 6

2 Identification . . . . . . . . . . . . . . . . . . . . 7

2.1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1.1 Product structure . . . . . . . . . . . . . . . . . . . . 7

2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 8

3 Installation . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Incoming acceptance, transport, storage . . . . . . . . . . 9

3.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . 10

3.2.1 Methods of installation . . . . . . . . . . . . . . . 10

3.2.2 Compressed air and water supply . . . . . . . . 10

3.2.3 Ambient conditions . . . . . . . . . . . . . . . . . . 11

3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . 11

3.3.1 Connecting the media . . . . . . . . . . . . . . . . 11

3.3.2 Preparing the chemicals . . . . . . . . . . . . . . . 12

3.4 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 17

4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.1 Preparing to wire . . . . . . . . . . . . . . . . . . . . 18

4.1.2 Power distribution . . . . . . . . . . . . . . . . . . . 19

4.1.3 Signal connection . . . . . . . . . . . . . . . . . . . 21

4.1.4 Power unit . . . . . . . . . . . . . . . . . . . . . . . . 22

4.1.5 Distributor connection . . . . . . . . . . . . . . . 23

4.1.6 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.2 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 24

5 Operation . . . . . . . . . . . . . . . . . . . . . . 25

5.1 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . 25

5.2 Display and keypad . . . . . . . . . . . . . . . . . . . . . . . . 26

5.3 Operation during measuring mode . . . . . . . . . . . . . 28

5.3.1 Recording mode . . . . . . . . . . . . . . . . . . . . 28

5.3.2 Spot view . . . . . . . . . . . . . . . . . . . . . . . . . 28

6 Commissioning . . . . . . . . . . . . . . . . . . 30

6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.2 CLR start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.3 Programming mode . . . . . . . . . . . . . . . . . . . . . . . . 31

6.3.1 Menu SETTING - RANGE DATA . . . . . . . . 32

6.3.2 Menu SETTING - SET CLOCK . . . . . . . . . 33

6.3.3 Menu SETTING - ALARM LIMITS . . . . . . . 33

6.3.4 Menu SETTING - BASIC DATA . . . . . . . . . 34

6.3.5 Menu SETTING - SET DEFAULTS . . . . . . . 35

6.3.6 Menu SETTING - MEASURING SITE . . . . 35

6.3.7 Menu LISTS - MIN MAX AVERAGE . . . . . 35

6.3.8 Menu LISTS - MAINTENANCE RECORD . 36

6.3.9 Menu LISTS - ALARM RECORD . . . . . . . . 37

6.3.10 Menu LISTS - SHOW COMPLETE

RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.3.11 Menu TEST - TEST OF INPUTS . . . . . . . . . 39

6.3.12 Menu TEST - TEST OF OUTPUTS . . . . . . . 40

6.3.13 Menu TEST - TEST FREQUENCY I/O . . . . 41

6.3.14 Menu TEST - TEST COM2 . . . . . . . . . . . . 41

6.3.15 Menu TEST - MEASUREMENT OFF . . . . . 42

6.4 Optimizing the analyzer . . . . . . . . . . . . . . . . . . . . . 43

6.4.1 Adjusting the measuring range . . . . . . . . . . 43

6.4.2 Influence on dosing pump P2 on the

measuring signal . . . . . . . . . . . . . . . . . . . . 43

6.4.3 Operating the analyzer with high salt loads 44

6.4.4 Adjusting the gas flow . . . . . . . . . . . . . . . . 44

6.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

TOCII CA72TOC

4Endress+Hauser

7 Maintenance . . . . . . . . . . . . . . . . . . . . 48

7.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.2 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.3 Topping up reagents . . . . . . . . . . . . . . . . . . . . . . . 53

7.4 Replacing the standard . . . . . . . . . . . . . . . . . . . . . . 53

7.5 Entering the concentration of the standard solution 54

7.6 Service software . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.7 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.7.1 Replacing the hoses on pumps P1 and P4 . . 55

7.7.2 Replacing the hose on pump P2 . . . . . . . . . 64

7.7.3 Replacing the hose on pump P3 . . . . . . . . . 67

7.7.4 Adjusting pump P2 . . . . . . . . . . . . . . . . . . 71

7.8 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.8.1 Adjusting the analyzer . . . . . . . . . . . . . . . . 74

7.8.2 Calibrating the analyzer . . . . . . . . . . . . . . . 76

7.8.3 Empty volume dosing . . . . . . . . . . . . . . . . 78

7.8.4 Adjusting the pH sensor . . . . . . . . . . . . . . . 81

7.9 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.9.1 Screen flushing . . . . . . . . . . . . . . . . . . . . . 85

7.9.2 Power flush . . . . . . . . . . . . . . . . . . . . . . . . 86

7.9.3 Bypass screen . . . . . . . . . . . . . . . . . . . . . . 87

7.9.4 Strip and separation chamber . . . . . . . . . . . 89

7.9.5 Opening the circuit . . . . . . . . . . . . . . . . . . 93

7.9.6 Combustion pipe . . . . . . . . . . . . . . . . . . . . 95

7.9.7 Leakage test . . . . . . . . . . . . . . . . . . . . . . 100

7.10 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

7.10.1 Replacing the acid filter . . . . . . . . . . . . . . 102

7.10.2 Replacing the gas filter . . . . . . . . . . . . . . . 104

7.10.3 Replacing the O2 filter . . . . . . . . . . . . . . . 106

7.10.4 Replacing the heated salt trap . . . . . . . . . . 108

8 Accessories . . . . . . . . . . . . . . . . . . . . 112

9 Troubleshooting . . . . . . . . . . . . . . . . 113

9.1 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . 113

9.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

9.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

9.4 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . 118

9.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

10 Technical Data. . . . . . . . . . . . . . . . . . 119

10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

10.2 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

10.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

10.4 Performance characteristics . . . . . . . . . . . . . . . . . 120

10.5 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

10.6 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

10.7 Mechanical construction . . . . . . . . . . . . . . . . . . . 120

Index . . . . . . . . . . . . . . . . . . . . . . . . . 121

TOCII CA72TOC Safety instructions

Endress+Hauser 5

1 Safety instructions

1.1 Designated use

The analyzer is a compact thermo-catalytic analytical measurement system. It is designed to monitor

the TOC content of industrial and municipal wastewater.

The device is particularly suitable for the following applications:

• Monitoring of industrial wastewater (e.g. in the inlet and outlet)

• Control of process wastewater

• Monitoring of industrial surface waters

• Municipal wastewater monitoring

• Recording the carbon load for nutrient dosing

Any other use than the one described here compromises the safety of persons and the entire

measuring system and is not permitted.

The manufacturer is not liable for damage caused by improper or non-designated use.

1.2 Installation, commissioning and operation

Please note the following items:

• Installation, commissioning, operation and maintenance of the measuring system must only be

carried out by trained technical personnel.

Trained personnel must be authorized for the specified activities by the system operator.

• Electrical connection must only be carried out by a certified electrician.

• Technical personnel must have read and understood these Operating Instructions and must

adhere to them.

• Before commissioning the entire measuring point, check all the connections. Ensure that

electrical cables and hose connections are not damaged.

• Do not operate damaged products and secure them against unintentional commissioning.

Mark the damaged product as being defective.

• Measuring point faults may only be rectified by authorized and specially trained personnel.

• If faults can not be rectified, the products must be taken out of service and secured against

unintentional commissioning.

• Repairs not described in these Operating Instructions may only be carried out at the

manufacturer’s or by the service organization.

1.3 Operational safety

The analyzer has been designed and tested to the highest standards and left the factory in perfect

functioning order.

Relevant regulations and European standards have been met.

As the user, you are responsible for complying with the following safety conditions:

• Installation instructions

• Local prevailing standards and regulations.

Immunity to interference

This instrument has been tested for electromagnetic compatibility in industrial use according to

applicable European standards.

Protection against interference as specified above is valid only for an instrument

connected according to the instructions in these Operating Instructions.

Safety instructions TOCII CA72TOC

6Endress+Hauser

1.4 Return

If the analyzer has to be repaired, please contact the responsible sales center.

If the analyzer has to be returned, please return it cleaned to the responsible sales center.

Please use the original packaging, if possible.

Please enclose the completed "Declaration of contamination" (copy the second last page of these

Operating Instructions) with the packaging and the transportation documents.

No repair without completed "Declaration of contamination"!

1.5 Notes on safety icons and symbols

Electrical symbols

#Warning!

This symbol alerts you to hazards that can cause serious damage to the instrument or to persons if

ignored.

"Caution!

This symbol alerts you to possible faults which could arise from incorrect operation. They could

cause damage to the instrument if ignored.

!Note!

This symbol indicates important items of information.

%Direct Current (DC)

A terminal at which DC is applied or through which DC flows.

&Alternating Current (AC)

A terminal at which (sine-form) AC is applied or through which AC flows.

)Ground connecting

A terminal which, from the user’s point of view, is already grounded using a grounding system.

*Protective ground terminal

A terminal which must be grounded before other connections may be set up.

bAlarm relay

Input

Output

DC voltage source

Temperature sensor

TOCII CA72TOC Identification

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2 Identification

2.1 Nameplate

Compare the order code indicated on the nameplate with the ordering structure and your order.

The nameplate bears the following information:

• Manufacturer data

• Order code (device version)

• Serial number

•Measuring range

• Outputs and communication

• Power supply

• Degree of protection

• (Permitted) ambient conditions

2.1.1 Product structure

Measuring range

A 0.25 to 600 mg/l TOC

B 1 to 2400 mg/l TOC

C 2.5 to 6000 mg/l TOC

D 5 to 12000 mg/l TOC

Y Special version according to customer specification

Sample transfer

1 1 measuring point

2 2 measuring points; time controlled

3 2 measuring points; external controlled

Operation mode

A Batch mode

Power supply

0 230 VAC, 50 Hz

1 115 VAC, 60 Hz

2 115 VAC, 50 Hz

3 230 VAC, 60 Hz

9 Special version according to customer specification

Sample preparation

A 1 x PA-2 PVC, 1 to 8 m3/h (4.4 to 35 gpm) wastewater (not with

CA72TOC-*2*********)

B 1 x PA-3 PVC, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with

CA72TOC-*2*********)

C 1 x PA-9 PP, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with

CA72TOC-*2*********)

D 2 x PA-2 PVC, 1 to 8 m3/h (4.4 to 35 gpm) wastewater (not with

CA72TOC-*1*********)

E 2 x PA-3 PVC, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with

CA72TOC-*1*********)

F 2 x PA-9 PVC, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with

CA72TOC-*1*********)

Y Special version according to customer specification

Language instrument, documentation

1German

2 English

CA72TOC- Order code

Iden tification TOCII CA72TOC

8Endress+Hauser

!Note!

To complete your order code, simply add the optional features to the end of order code. If you have

any questions, please contact your local sales office.

2.2 Scope of delivery

The scope of delivery comprises:

• 1 analyzer CA72TOC

• Tool kit for leak check

• Tool kit to remove the glass ball and the media

• Acid filter kit

• Kit for commisioning of stripper and separation chamber

• Maintenance kit for furnace

• Hose kit for inlet and outlet

• 1 canister 5 liter

• 2 canisters 2 liter

•3 covers for canisters

• Key for door lock

• Connection box EMV

• Measuring glas 10 ml

• Sponge

• Safety glasses

• Gloves, acid-proof and base proof

• Silicone

• Operating Instructions

If you have any questions, please contact your supplier or your local sales center.

2.3 Certificates and approvals

Declaration of conformity

The product meets the requirements of the harmonized European standards. It thus complies with

the legal requirements of the EC directives.

The manufacturer confirms successful testing of the product by affixing the 4 symbol.

Carrying gas (optinal, select one option only)

E1 CO2-scrubber

E2 CO2-scrubber + compressor

Analyzer mounting (optinal, select one option only)

F1 Wall mounted

F2 Stand

Accessory mounted (optinal, multiple selection possible)

G1 Sample predilution

G4 Heated salt trap

G5 Pipe back flushing

G6 Standby mode PA-2/-3 failure

G7 sample valve for aggressive media

Accessory enclosed (optinal, multiple selection possible)

H1 230 VAC furnace conditioning station (not with CA72TOC-***1******* and not with

CA72TOC-***2*******)

H2 115 VAC furnace conditioning station (not with CA72TOC-***0******* and not with

CA72TOC-***3*******)

H3 Standard furnace (not with CA72TOC-********G4**)

H4 Furnace for heated salt trap

TOCII CA72TOC Installation

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3 Installation

3.1 Incoming acceptance, transport, storage

• Make sure the packaging is undamaged!

Inform the supplier about any damage to the packaging.

Keep the damaged packaging until the matter has been settled.

• Make sure the contents are undamaged!

Inform the supplier about damage to the contents. Keep the damaged products until the matter

has been settled.

• Check that the order is complete and agrees with your shipping documents.

• The packaging material used to store or to transport the product must provide shock protection

and humidity protection. The original packaging offers the best protection. Also, keep to the

approved ambient conditions (see "Technical data").

• If you have any questions, please contact your supplier or your local sales center.

Installation TOCII CA72TOC

10 Endress+Hauser

3.2 Installation conditions

3.2.1 Methods of installation

The analyzer can be mounted in three ways:

• As a standalone desktop unit

• Mounted to the wall (option F1)

• Mounted on a base frame with wheels (option F2)

a0012435

Fig. 1: Dimensions

3.2.2 Compressed air and water supply

When operating the analyzer, only use tonnage oxygen (gas in cylinders) or compressed air free from

carbon dioxide.

The compressed air must be dry and meet the following conditions:

• < 3 ppm CO2

• < 3 ppm hydrocarbons

• The pressure must be 2 bar (29 psi) constantly.

• The pressure tolerance is ±5 %.

• The compressed air volume is 650 to 750 cm3/min (1.37 to 1.6 ft3/hr).

• If compressed air is supplied in the building, the pipe must be fitted with a CO2 scrubber (infeed

pressure 4 to 10 bar (58 to 145 psi) and a pressure regulator.

• Connection: 4/6 mm DN

The water is connected via a 6/8 mm DN or G3/8 coupling. The pressure must be between 2 and

4 bar (29 to 58 psi).

400 (15.8)

600 (23.6)

785 (30.9)

1010 (39.8)

1558 (61.3)

mm (inch)

50

(1.97)

TOCII CA72TOC Installation

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3.2.3 Ambient conditions

• The analyzer requires a drain beneath the device. Use a 6/8 mm PTFE drain pipe. No

backpressure should form in the drain.

• An exhaust gas connection is required in enclosed spaces. Halogens or other vapors may not build

up in this area. No backpressure should form in the 4/6 mm connection.

• Ambient temperature range: 5 to 35 °C (41 to 95 °F)

• Humidity: 10 to 90 %, non-condensating

• It should be possible to access the analyzer from the front and rear.

3.3 Installation instructions

#Warning!

Danger! Risk of electric shock!

Do not connect the analyzer to the power grid before all the installation work has been completed

and the liquid and gas media are connected.

Follow the instructions in the "Wiring" section to connect the analyzer to the electricity supply.

3.3.1 Connecting the media

a0012643

Fig. 2: Connections on the left side panel

1 Power cable

2 Gas outlet

3 Gas connection

4 Water connection

5 Bypass rinse water

6 External grounding

7 Standard C2 connection

8 Standard C1 connection

9 Acid connection

10 Condensate drainage

11 Sample supply

12 Sample drainage

1

2

3

4

5

6

7

8

9

10

11

12

Installation TOCII CA72TOC

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Sample supply

Sample is supplied via a 3/8" connection on the left side panel (item 11).

!Note!

Additional connections are required if sample conditioning takes place (see instructions for sample

conditioning).

Analyzer sample drainage

Sample is drained off unpressurized via a DN 6/8 mm hose connection (compression fitting) on the

left side panel (item 12) into an open channel or pipe.

Condensate drainage

Condensate is drained off via a hose gland (PE, DN 1.6/3.2 mm, scope of delivery) on the left side

panel (item 10).

Gas outlet

Gas escapes via a hose gland (DN 4/6 mm) on the left side panel (item 2).

3.3.2 Preparing the chemicals

#Warning!

Accidents with chemicals can kill, blind, burn, or damage lungs. Many chemicals are poisonous or

corrosive; some are explosive, by themselves or in combination. Others are hazardous because they

can be absorbed easily through skin or the respiratory system. When working with any chemicals,

always observe the precautions in the section "Precautions regarding use of chemicals".

The analyzer requires the following chemical solutions:

• Stripper solution

Nitric acid HNO3 conc. 25 %

This acid is used to acidify the sample. In this way, the carbonate ion CO3 is converted to CO2

and the dissolved CO2 is removed from the solution (TIC stripping).

• Parent solution

Potassium hydrogen phthalate (KHP) with a concentration of 5 000 mg TOC/l

This parent solution for calibrating and adjusting the analyzer is used as a diluted standard in the

measuring range from 0 to 600 mg TOC/l. In the event of high KHP concentrations and sample

acidification (pH < 2.5), there is the risk of KHP precipitating in the solution.

• Parent solution

Citric acid with a concentration of 100 000 mg TOC/l

This parent solution for calibrating and adjusting the analyzer is used as a diluted standard in the

measuring range from 600 mg TOC/l onwards.

The stripper solution and the parent solutions are available from Endress+Hauser (see "Accessories"

chapter).

TOCII CA72TOC Installation

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Specifying the standard concentrations

The right choice of standard concentration is key to the accuracy of the measurement method.

Before you specify the concentrations of the standard solutions, determine what concentration

range the device should measure. The most common concentrations should be covered by the

standard solutions.

Please note, however, that there should be a concentration ratio of between 1:4 and 1:20 between

the two standard solutions.

If a limit value is to be monitored, it makes sense for the concentration of the standard to correspond

to the concentration of a limit value as this guarantees maximum precision when monitoring.

!Note!

Please note that no measurement method can provide accurate measurement results over a span

greater than 1:30.

Example:

20 and 200 mg/l should be selected here as the standard solutions. The system can then measure

accurately in the range from 10 to 300 mg/l (taking the measuring range of the system into

account). A higher measured value deviation can be expected below a concentration level of

10 mg/l and above a concentration level of 300 mg/l.

Precautionary measures when working with chemicals

• Carefully read the "Material Safety Data Sheet" (MSDS) that is supplied with every chemical to

determine the hazards posed and what precautionary measures have to be taken. If you are not

sure what risks are associated with the chemical, please ask appropriately qualified experts.

• Never prepare chemicals on your own. You may need assistance in the event of an accident. For

this reason, always make sure that someone is close-by. Only prepare chemicals in a properly

equipped laboratory.

• When preparing chemicals always wear protective goggles, rubber gloves and a rubber apron. In

addition, wear a dust mask or face shield when working with fine-powder chemicals.

• Chemicals or solutions that are used with the analyzer (or another process analysis device) should

never be inhaled, tasted or swallowed.

• When preparing solutions, you must always label the containers appropriately, indicating the

contents and the date of preparation. Dispose of unlabeled or expired solutions in accordance with

local regulations and guidelines.

• Some chemicals are very reactive when combined with other substances or dissolved in water

and cause explosions, fire or heat to occur, or dangerous gases, foams or sprays to be released.

Avoid the risk of dangerous accidents occurring: If you do not know how certain chemicals react,

make sure you do not mix them with other substances. Never mix chemicals that are known to

react severely.

Concentration to be measured: 3 to 300 mg/l

Most frequent concentration: 50 to 150 mg/l

Limit value to be monitored: 200 mg/l

Installation TOCII CA72TOC

14 Endress+Hauser

Reagent quality

!Note!

Reagent quality can affect the accuracy of measurements. For this reason, follow the steps outlined

below to ensure reagent quality.

• For 10, 100, and 500 mg/l units, use the best grade of reagents. For 1,000, 5,000, and

10,000 mg/l units, ordinary commercial grade acids and persulfate are suitable. For the KHP

calibration standard, use reagent grade or better for all units. For the 1,000, 5,000 and

10,000 mg/l units, you can experiment with quality once you have established repeatability, and

as long as the results are not affected. Lower grades of acid and persulfate may be acceptable.

• Rinse all glassware and plastic containers thoroughly with deionized water. For best results,

acid-wash and rinse them again before use.

• Use good scales and weigh the standard as accurately as possible before mixing. Keep containers

closed to prevent contamination and deterioration.

• Accurate preparation of the calibration standard is essential for accurate calibration of the

analyzer. Inaccurate preparation of the standard will result in an erroneous calibration, which in

turn will yield worthless results.

• The KHP calibration standards for 10 and 100 mg/l deteriorate rapidly in solution. Keep

containers closed when not in use, and store in a cool place (such as a refrigerator). Heat and

exposure to air can ruin sensitive solutions quickly.

Preparing potassium hydrogen phthalate

"Achtung!

Potassium hydrogen phthalate (KHP) can irritate the skin and cause problems with the eyes or

respiratory channel. Do not inhale the powder and do not attempt to ever swallow any of the

solution prepared.

Shelf life: Relatively stable, depending on the concentration. (Stability decreases with decreasing

concentration; refrigeration is recommended.)

Concentrations: Depends on the application.

Procedure:

For an organic carbon solution with a concentration of 5,000 mg/l, dissolve 10.627 g of p.a. (or

better) KHP in 500-700 ml of deionized water in a 1-liter volumetric flask (other concentrations of

the solution are listed in the table below). Once the chemical has dissolved, add 4 ml of H2SO4 and

top up the mixture with water until the 1-liter mark is reached. Stir the solution once more. Label

the container, indicating the contents and the date of preparation.

mg/l carbon g KHP Volume

5,000 10.627 1 l

1,000 2.1254 1 l

500 1.0627 1 l

100 0.21254 1 l

10 0.021254 1 l

TOCII CA72TOC Installation

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The solution with a concentration of 5,000 mg/l is stable (particularly when stored in a cool dark

place). It is recommended to perform serial dilutions on the basis of a standard substance of

5,000 mg/l to reduce the concentrations if needed. Example:

• If 10 ml of a solution with a concentration of 5,000 mg/l is diluted with 90 ml deionized water,

this results in a concentration of 500 mg/l.

• If 10 ml of a solution with a concentration of 500 mg/l is diluted with 90 ml deionized water,

this results in a concentration of 50 mg/l.

• If 10 ml of a solution with a concentration of 50 mg/l is diluted with 90 ml deionized water, this

results in a concentration of 5 mg/l.

Serial dilution is the preferred method to create lower concentrations instead of diluting 1 ml of the

5,000 mg/l solution with 99 ml deionized water. The latter method can result in measurement

errors.

"Caution!

Please note the following:

• Storable parent solutions with concentrations of 1,000 and 5,000 mg/l are relatively stable for

several weeks at room temperatures. Parent solutions must be stored in cool dark place.

• In the case of a solution with a concentration of 10 mg/l, on the other hand, the quality starts to

deteriorate at room temperature within 3 to 5 days. To give the KHP standard solutions greater

stability, 4 ml H2SO4 (4 mol) can be added to one liter.

• If parent solutions with a high KHP content acidify, there is the risk of the KHP precipitating.

• Make sure to keep the container with the crystalline KHP sealed at all times. If the crystalline KHP

comes into contact with the air, it absorbs water very quickly and must be dried before use.

Otherwise you will get inaccurate measurements since the concentration of carbon is lower in the

hydrous salt. KHP that has come into contact with air must be dried for one hour at 105 °C

(221 °F).

Preparing the parent solution from citric acid

"Caution!

• Nitric acid is highly caustic.

• Citric acid can irritate the skin and eyes and cause respiratory problems. Never attempt to swallow

any of the solution prepared.

• Wear protective goggles, gloves and protective clothing.

• Always add acids to water, not vice versa.

Shelf life: Storable parent solutions with concentrations of 100,000 mg/l are stable for 6 months

if stored in a cool, dark place at 4 to 8 °C (40 to 46 °F). Prepared standard solutions must be used

within four weeks even if stored in a cool, dark place.

Concentrations: Depends on the application.

Material:

• 1-liter volumetric flask

• Citric acid monohydrate C6H8O7 & H2O (purity: p.a.)

• Nitric acid HNO3 (65 %, purity: p.a.)

Procedure:

For an organic carbon solution with a concentration of 100,000 mg/l, dissolve 291.6 g of citric acid

monohydrate in 500 ml of deionized water in a 1-liter volumetric flask (other concentrations of the

solution are listed in the table below). Carefully add 55.0 ml (77.0 g) of nitric acid. Once the

chemicals have dissolved, top up the mixture with water until the 1-liter mark is reached. Stir the

solution once more. Label the container, indicating the contents and the date of preparation.

mg/l carbon Citric acid in g Nitric acid in ml Volume

100,000 291.6 55.0 1 l

50,000 145.8 55.0 1 l

10,000 29.16 55.0 1 l

Installation TOCII CA72TOC

16 Endress+Hauser

The solution with a concentration of 100,000 mg/l is stable (particularly when refrigerated). It is

recommended to perform serial dilutions on the basis of a standard substance of 100,000 mg/l to

reduce the concentrations if needed. Example:

• If 10 ml of a solution with a concentration of 100,000 mg/l is diluted with 90 ml deionized water,

this results in a concentration of 10,000 mg/l.

• If 10 ml of a solution with a concentration of 10,000 mg/l is diluted with 90 ml deionized water,

this results in a concentration of 1,000 mg/l.

• If 10 ml of a solution with a concentration of 1,000 mg/l is diluted with 90 ml deionized water,

this results in a concentration of 100 mg/l.

Serial dilution is the preferred method to create lower concentrations instead of diluting 1 ml of the

100,000 mg/l solution with 99 ml deionized water. The latter method can result in measurement

errors.

Preparing the stripping reagent

Stripping reagent dosing is regulated via the pH sensor. The regulation range of the dosing is from

the minimum feed rate of the acid pump to approximately 1000 times this amount. The necessary

acid quantity varies greatly from measuring place to measuring place. Ideally, the strength of the

acid in the feeder tank should be set in such a way that the system can regulate in both directions,

but the regulation range should be higher for higher volumes of acid dosed.

Regulation aid:

The acid feeder is typically in the region of a few % acid. The aim should be to achieve a feed rate

of 2 to 5 % for pump P3 (the current feed rate can be read in the

PROGRAMMING/TEST/OUTPUT/PUMPS menu).

To set the acid concentration, an acid is prepared as follows as the starter point:

• Fill the acid hose

• Start measuring operation with a real sample

• Allow the acid dosing system to regulate

• Feed rate > 2 % < 5 %, note the acid concentration and use for future mixtures

• Feed rate < 2 % acid concentration, dilute preparation

• Feed rate > 5 % acid concentration, increase the concentration of the preparation

• Replace the contents of the acid hose

• Allow the acid dosing system to regulate, read off the feed rate

Deionized water (ml) HNO3 25 % (ml) HNO3 concentration

Increase concentration 500 + 125 5.0 %

+ 125 8.3 %

+ 125 10.7 %

+125 12.5 %

Dilute 500 +125 5.0 %

+ 500 2.8 %

+1000 1.5 %

+2000 0.8 %

TOCII CA72TOC Installation

Endress+Hauser 17

Use of other acids

• Nitric acid

Nitric acid does not form lyophobic salts in the strip chamber. The resulting nitrogen oxides in

the combustion gas are filtered out with an acid filter upstream from the IR detector.

• Phosphoric acid

Phosphoric acid is a low-volatility, odorless acid that generates practically no precipitate. After

combustion, substances are formed that are filtered out completely in the heatable salt trap.

• Sulphuric acid

Sulphuric acid is a low-volatility, odorless acid. When using sulphuric acid, precipitate can be

expected with alkaline earth metal ions. In addition to the sulfur dioxides, salts also occur as a

reaction product downstream from the furnace. These salts are easily removed in the heatable salt

trap. Gypsum can also occur if the water is very hard.

• Hydrochloric acid

Hydrochloric acid is a volatile acid with a pungent odor. Salts do not precipitate in the strip

chamber. During combustion, salts occur (heatable salt trap) as does HCl gas, which is absorbed

in the condensate.

3.4 Post-installation check

• After installation, check that all connections are tightly fitted and are leak-resistant.

• Check all hoses for damage.

Wiring TOCII CA72TOC

18 Endress+Hauser

4 Wiring

4.1 Electrical connection

#Warning!

• The electrical connection must only be carried out by a certified electrician.

• Technical personnel must have read and understood the instructions in this manual and must

adhere to them.

• Ensure that there is no voltage at the power cable before beginning the connection work.

4.1.1 Preparing to wire

#Warnung!

Before connecting the device, make sure that the line voltage matches the voltage indicated on the

nameplate.

The following versions are available:

• 115 V AC 50 Hz

• 115 V AC 60 Hz

• 230 V AC 50 Hz

• 230 V AC 60 Hz

#Warning!

Danger! Risk of electric shock! Disconnect the device from the power supply system (disconnect the

mains plug). The line filter, the overvoltage module and the main switch are still connected to the

power supply even when the main switch is switched off.

#Warning!

Ensure that the analyzer is sufficiently grounded via the mains connection.

Condition: 50 V < R*Imax

Imax = is the maximum current above which the residual current circuit breaker is triggered.

R = the resistance between protective ground and device ground.

If these conditions cannot be ensured, the device must be grounded on site.

You must make the following connections:

• Alternating current connection via mains plug

• External grounding if necessary

• Analog 0/4 to 20 mA outputs

•Binary outputs

• Binary inputs

•RS-232

The signal connections are located in the EMC screening box on the right-hand side of the cabinet.

The connection for the external ground is located at the bottom on the left-hand side of the cabinet.

TOCII CA72TOC Wiring

Endress+Hauser 19

4.1.2 Power distribution

a0011954-en

Fig. 3: Power distribution wiring diagram

+-

23

12345678

2

3

1

4

44

+

-

13 14 23 24 33 34 43 5344 54 63 64 73 74 8483

1234 6789 1112510 13LNPE

764 12 13

25118

A9 10

14

40

39

15

terminal strip

relay module

relay 3

relay no.

fuse 16 A

rel. 3A 24VDC

relay 4A

adapter

relay 4A

relay 230V DC

Wiring TOCII CA72TOC

20 Endress+Hauser

Terminal strip assignment:

Relay module assignment:

The power distribution is located at the back in the top door.

Terminal Description

A Main switch, power distribution

4 Solenoid valve 3 - stripping gas

5 Tube furnace regulator

6 Peltier cooler regulator

7 Membrane compressor

9 Heated salt trap regulator

10 Solenoid valve 4, standard 1 + 2

11 Solenoid valve 7, carrier gas

12 Solenoid valve 2, strip chamber rinsing

13 Solenoid valve 5, bypass screen rinsing

14 Solenoid valve 1, sample/standard

15 Solenoid valve 6, channel 1/channel 2 (optional)

40 Solenoid valve 8, dosing

Relay No. Relay type Function

1 4A Solenoid valve 1, sample/standard

2 4A Solenoid valve 2, strip chamber rinsing

3 25A Solenoid valve 3, stripping gas, tube furnace regulator, heated salt trap regulator,

Peltier cooler regulator, membrane compressor

4 4A Solenoid valve 4, standard 1 + 2

5 4A Solenoid valve 5, bypass screen rinsing

6 4A Solenoid valve 6, two-channel changeover (optional)

7 4A Solenoid valve 7, carrier gas

8 3A Solenoid valve 8, dosing

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Endres+Hauser TOCII CA72TOC Operating instructions

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