wtw PROTOC 200 Operating instructions

Brand: wtw

Model: PROTOC 200

Type: Operating instructions

PROTOC 200

TOC Analyzer

ba43200e01 11/00

Operating Manual

0 - 2

Status at printing Our policy of continuous development ensures the advanced

technology and high quality standard of our equipment. As a result, this

operating manual may not correspond exactly to your equipment.

Furthermore, errors in the contents cannot be ruled out. Please be

aware that the information, figures and descriptions in this manual

cannot be used as the basis for legal claims.

Reproduction – including excerpts – only upon express written consent

of WTW GmbH & Co. KG, Weilheim.

Printed in Germany.

PROTOC 200 Contents

0 - 3

1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Non-intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3 Use of safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.4 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Preparing solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.1 Reagent solution . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.2 Standard solution . . . . . . . . . . . . . . . . . . . . . . . 12

3.2.3 Cleaning solution . . . . . . . . . . . . . . . . . . . . . . . . 13

3.3 Prerequisites for installation . . . . . . . . . . . . . . . . . . . . . . 14

3.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.4.1 Wall assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.4.2 Sample conditioning . . . . . . . . . . . . . . . . . . . . . 18

3.4.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . 19

3.4.4 Connecting the carrier gas . . . . . . . . . . . . . . . . 21

3.4.5 Connecting the outlet . . . . . . . . . . . . . . . . . . . . 22

3.4.6 Connecting the reagent solution . . . . . . . . . . . . 22

3.4.7 Connecting the standard solution . . . . . . . . . . . 23

3.4.8 Connecting the cleaning solution . . . . . . . . . . . 23

3.5 Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.6 Checklist for commissioning the equipment . . . . . . . . . . 27

3.7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Operation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.3 Shutting down the system . . . . . . . . . . . . . . . . . . . . . . . 32

5 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.1 Controller function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.2 Sensor setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.2.2 Selecting the units . . . . . . . . . . . . . . . . . . . . . . . 34

5.2.3 Changing the calibration point . . . . . . . . . . . . . . 35

5.2.4 Setting the measuring range . . . . . . . . . . . . . . . 36

5.2.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.2.6 Zeroing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.2.7 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.2.8 Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Contents PROTOC 200

0 - 4

5.3 Alarm setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.3.2 Setting the nominal alarm values . . . . . . . . . . . . 42

5.3.3 Setting up the access code . . . . . . . . . . . . . . . . 43

5.4 Display settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.5 Controller setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5.2 Setting the date/time . . . . . . . . . . . . . . . . . . . . . 46

5.5.3 Configuring the analog output . . . . . . . . . . . . . . 46

5.5.4 Setting the output voltage/current range . . . . . . 47

5.5.5 Serial interface (option) . . . . . . . . . . . . . . . . . . . 48

6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.1 Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.2 Six-monthly maintenance:

Replacing all pump tubes . . . . . . . . . . . . . . . . . . . . . . . . 49

6.3 Replacing individual pump tubes . . . . . . . . . . . . . . . . . . 51

7 What to do if... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.1 The display responds slowly or not at all to the

calibration solution or sample . . . . . . . . . . . . . . . . . . . . . 52

7.2 Calibration and/or zeroing does not function . . . . . . . . . 52

7.3 Unstable readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.1 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8.4 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9.1 Flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9.2 Socket connections for the analog output . . . . . . . . . . . . 60

PROTOC 200 Overview

1 - 5

1 Overview

View of equipment

Figure 1-1PROTOC 200 Analyzer

Figure 1-2PROTOC 200 Controller

Overview PROTOC 200

1 - 6

Function The PROTOC 200 is used to continuously measure organic carbon

content (TOC = total organic carbon) in aqueous samples. The mea-

surement procedure consists of the following steps:

l A reagent is added to the sample. The reagent contains sodium per-

sulfate and nitric acid or ortho-phosphoric acid.

l The sample and reagent mixture is sparged with a carrier gas (usu-

ally compressed air or nitrogen). This removes inorganic carbon and

dissolved carbon dioxide. The remaining liquid contains only organic

carbon compounds.

l The remaining liquid is pumped into the reaction vessel.

l A strong ultraviolet light source in the reaction vessel promotes oxi-

dation of the organic carbon compounds by the persulfate. This pro-

cess produces carbon dioxide gas.

l Carrier gas flows in through the reaction vessel base and transports

the carbon dioxide through a gas drying system and on to an infra-

red carbon dioxide detector. The amount of carbon dioxide pro-

duced is directly proportional to the organic carbon content of the

sample.

The PROTOC 200 can also be used to determine the total carbon con-

tent (TC = total carbon). The sample and reagent mixture is pumped di-

rectly into the reaction vessel without prior sparging.

The measuring signal is transmitted to the controller. The controller is

equipped with a signal output used in the control of external processes.

The PROTOC 200 is calibrated by passing a standard solution through

the analyzer. The standard solution contains a known quantity of car-

bon. The IR detector is adjusted until the analyzer displays the correct

reading. Solenoids switch between the sample and the standard solu-

tion.

Measurement output Measuring signals can also be output to external equipment (e.g. re-

corder, PC) via a 4 - 20 mA or 0 - 10 VDC (selectable) analog output.

PROTOC 200 Safety

2 - 7

2 Safety

This chapter contains general instructions to be followed during the in-

stallation, operation and maintenance of the equipment. It is absolutely

essential that users read this chapter prior to working with the equip-

ment. Always keep this operating manual in the vicinity of the equip-

ment!

2.1 Intended use

The intended use of this analyzer comprises

l determining TOC and TC in aqueous samples

l measuring surface water.

The intended use of the analyzer only covers the operation and running

as described in this operating manual.

2.2 Non-intended use

Non-intended use includes all methods of operating and running this

equipment that exceed the scope of operation as described in this op-

erating manual regarding the analyzer or individual components.

2.3 Use of safety symbols

Warning

Denotes information that must be followed in order to avoid serious per-

sonal injury or death.

Attention

Denotes information that must be followed in order to avoid slight per-

sonal injury or damage to equipment or the environment.

Note

Denotes tips regarding the equipment and its use to simplify operation.

Note

Denotes references to information in other sections of this operating

manual or other documents.

Safety PROTOC 200

2 - 8

2.4 General safety instructions

Function and operating

safety

The analyzer left the factory in perfect condition. Perfect function of the

equipment and operating safety can only be ensured if the environmen-

tal conditions and connection specifications stated in Chapter 8 T

ECH-

NICAL DATA, are met.

Perfect function and operating safety of this equipment can only be en-

sured if standard safety precautions as well as the special safety in-

structions in this operating manual are observed when using the

equipment.

Warning

Failure to comply with the instructions and safety notes in this operating

manual may lead to personal injury to operating personnel!

Warning

All maintenance and repair work that goes beyond the activities de-

scribed in Chapter 6 M

AINTENANCE, may only be carried out by techni-

cally qualified personnel authorized by the WTW company.

Technical condition The operator/user is obliged to continuously monitor the general tech-

nical condition of the analyzer (externally visible flaws and damage,

and changes in operational behavior).

Safe operation If it appears that the equipment cannot be safely operated, it must be

shut down and protected against inadvertent operation!

For example, the equipment cannot be safely operated when it:

l appears to have been damaged during transportation,

l has been stored improperly,

l shows visible signs of damage, or

l is not operating correctly.

Please contact the supplier in case of doubt.

Operating personnel The PROTOC 200 was developed for use in the environmental and in-

dustrial sectors. We assume that, through occupational training and ex-

perience, equipment operators are familiar with the safety precautions

required when handling chemicals.

PROTOC 200 Safety

2 - 9

Operator obligations The operator of the analyzer must ensure that the following laws and

guidelines are adhered to when handling hazardous substances:

l EG guidelines for industrial safety

l National laws regarding industrial safety

l Accident prevention regulations

l Safety data sheets of the chemicals and consumable substances

used.

2.5 Hazards

Warning

Touching electric components inside the analyzer during operation

may cause life-threatening injury due to electric shock. Switch off the

lamp before removing the lamp shield. Electric components may only

be serviced by trained and technically qualified personnel.

Warning

The source materials for preparing the reagent solution are highly cor-

rosive. Furthermore, sodium persulfate powder is inflammable when it

comes into contact with combustible substances. Observe the safety

data sheets provided by the chemical manufacturer and strictly comply

with the precautionary measures described therein.

Warning

The cleaning solution is corrosive and irritates skin and eyes. Avoid any

contact when handling the cleaning solution. Observe the safety data

sheets provided by the chemical manufacturer and strictly comply with

the precautionary measures described therein.

Attention

The pump motor contains a high-speed rotating fan. Touching the fan

during operation may cause severe injury to fingers. Never operate the

pump without first installing the finger guard.

Attention

The light source in the reaction vessel emits ultraviolet light during op-

eration. Direct exposure may lead to eye injury. Only operate the UV

lamp with the shield mounted on the reaction vessel. Never operate the

UV lamp outside of the reaction vessel.

Safety PROTOC 200

2 - 10

PROTOC 200 Installation

3 - 11

3 Installation

Attention

The equipment may only be erected, installed and set up by trained and

technically qualified personnel after careful study of this operating man-

ual.

The manufacturer reserves the right to reject warranty claims if these

requirements are not complied with.

3.1 Scope of delivery

Please check the packing list included to ensure that all parts listed

have been received.

3.2 Preparing solutions

3.2.1 Reagent solution

For operation, the analyzer requires a sodium persulfate solution that

has been acidified with nitric acid (preferred) or phosphoric acid.

Use only high quality concentrated nitric acid or phosphoric acid to pre-

pare the reagent solution. Water for dilution should be deionized or dis-

tilled. Tap water may be used for applications in the higher measuring

ranges (from 200 ppm upwards).

Warning

The starting materials used in the preparation of reagent solutions are

highly corrosive. Furthermore, sodium persulfate powder is inflamma-

ble when it comes into contact with combustible materials. Observe the

safety data sheets provided by the chemical manufacturer and strictly

comply with the precautionary measures described therein.

Warning

The oxidation reagent contains sodium persulfate. The reagent is cor-

rosive and irritates skin and eyes. Avoid any contact when handling the

reagent. Wear suitable protective gloves and goggles.

Installation PROTOC 200

3 - 12

The table lists the quantities of chemicals that are required:

Prepare the reagent solution as follows:

Preparing the reagent

solution

Note

A higher acid concentration in the reagent solution is required for appli-

cations in which the proportion of inorganic carbon (inorganic carbon =

IC) to the TOC is very high (IC > 50, TOC < 10), or for applications that

have a high pH value. We recommend doubling the acid quantities in

the above table, i.e. 200 ml acid to 20 liters water.

Note

The reagent solution has a shelf life of several weeks.

3.2.2 Standard solution

You will need a standard solution of known carbon concentration to cal-

ibrate the analyzer. Usually a supply of the standard solution with 1000

ppm carbon is prepared.

Prepare the standard solution as follows:

Preparing the standard

solution

Concentra-

tion

Sodium

persulfate

Water for

dilution

Acid

2.5 % 500 g 20 liters 100 ml

5 % 1 kg 20 liters 100 ml

10 % 2 kg 20 liters 100 ml

1 Fill a clean 5 or 10 liter container half full with water.

2 Add the sodium persulfate and dissolve it completely. Add

more water if required.

3 Add the acid.

4 Transfer the solution to the reagent container and fill it to the

required level with water.

1 Ensure that the accessories and the container are free from or-

ganic contamination.

PROTOC 200 Installation

3 - 13

Note

The concentrated stock solution has a shelf life of 4 to 6 weeks if refrig-

erated.

Note

If higher concentrations are required, prepare the solution with a multi-

ple of the weight specified above.

3.2.3 Cleaning solution

You will need a cleaning solution to clean the analyzer plumbing sys-

tem. The type of cleaning solution required depends on the application

and is specified upon ordering.

2 Weigh out 2.125 g reagent grade, anhydrous potassium hydro-

gen phthalate (C8H5O4K) and transfer it to a 1l graduated

flask.

3 Add distilled or deionized water.

4 Add 1 ml reagent grade, concentrated phosphoric acid.

5 Top up to the 1l mark with water.

6 Mix thoroughly.

7 Label the bottle with the contents and preparation date and

store it in a refrigerator.

8 Dilute the standard solution as required for calibration.

Installation PROTOC 200

3 - 14

3.3 Prerequisites for installation

Location l The equipment is not designed for outdoor use.

l The equipment should be installed as close as possible to the loca-

tion where the sample is taken to avoid any changes to the sample

en route to the analyzer and to minimize the inlet lag time.

l The analyzer should be protected against strong vibrations (as may

be caused by large motors, pumps, etc.) since these may negatively

affect performance.

l There must be an open and pressure-free drain.

PROTOC 200 Installation

3 - 15

3.4 Installation

3.4.1 Wall assembly

Attention

Do not shorten the tubes included; their full length is required for fas-

tening the swage locks.

Figure 3-1PROTOC 200 dimensions (given in mm)

Mounting the analyzer

and controller

Dimensions and space

requirements

1 Attach the analyzer securely to the mounting wall using the 4

wall fixtures. Bear in mind that the unit must be accessible from

all sides.

2 Attach the controller fixture to the mounting wall; if possible, it

should be mounted close to the analyzer.

3 Place the controller onto the wall fixture.

4 Space requirements for the controller are shown in the dimen-

sioned views in Figure 3-1. Figure 3-2 presents a typical wall

assembly with the required drilled holes.

Installation PROTOC 200

3 - 16

Figure 3-2Typical wall assembly with drilled holes (dimensions in mm)

203

101.5

ca.1800

647

457

min. 200

Analyzer

Controller

Typical wall assembly

5 Connect the analyzer power cable to Connection A

(see Figure 3-3).

6 Connect the controller to Connection B

(see Figure 3-3) on the analyzer.

PROTOC 200 Installation

3 - 17

Connections

Figure 3-3Connections

Warning

The solution flowing from the drain contains acid and oxidizing sub-

stances. It causes severe injury to eyes and skin upon contact. Avoid

any direct contact with the draining liquid. Wear suitable protective

gloves and goggles.

Connection Function

A Power supply

B Signal output to controller

C Carrier gas inlet

D System outlet

E Sample inlet

F Standard inlet

G Reagent inlet

H Outlet opening

I Ventilation

J Dryer and U-tube ventilation

K Cleaning liquid inlet

L Cleaning liquid outlet

Installation PROTOC 200

3 - 18

3.4.2 Sample conditioning

The PROTOC 200 Analyzer configuration depends on:

l the measuring objective

l the physical arrangement around the equipment

l the nature of the sample

The particle size in the sample to be analyzed should be less than 100

micrometers. Appropriate filtering should be employed which takes the

following into account:

l PROTOC 200 performance depends upon the integrity of the sam-

ple. Each individual installation may require its own unique sample

processing system.

l Ideally, the sample intake into the PROTOC 200 at the sampling lo-

cation will be many times larger than the intake actually required for

measurement. This serves to shorten the time the sample takes to

reach the analyzer (lag time), i.e. to avoid any change in the sample

en route to the analyzer. It also improves the functioning of sample

conditioning and allows the use of prefabricated pumps and tubes.

l Some applications require a cleaning cycle in which the sample flow

tube in the analyzer is rinsed with a cleaning solution. This serves to

prevent blockage due to the build-up of fine particles or to remobilize

deposits or grease.

1 Install the pumping or filtering system suitable for the applica-

tion and connect it to the sample inlet (see Connection E, Fig-

ure 3-3). The sample should not be flowing at this point.

PROTOC 200 Installation

3 - 19

3.4.3 Electrical installation

Warning

It is essential that the analyzer be correctly earthed.

Electrical work may only be carried out by technically qualified person-

nel.

Prior to connecting the equipment, ensure that the data of the mains

power socket correspond to the specifications stated in the T

ECHNICAL

ATA section of this manual. The mains power socket must have a

ground cable connection.

Figure 3-4IR detector

1 Before connecting the equipment, ensure that the IR detector

switch (1) located in the analyzer is set to OFF.

Installation PROTOC 200

3 - 20

Figure 3-5Lamp switch

Figure 3-6Pump switch and main switch

2 Ensure that the lamp switch (2) is set to OFF.

3 Ensure that the pump switch (3) is set to OFF.

4 Plug in the analyzer power cable.

5 Switch on the main switch (4).

6 Switch on the IR detector (1). The warm-up period begins.

7 Make the remaining connections during this period.

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wtw PROTOC 200 Operating instructions

wtw PROTOC 200 Operating instructions

wtw PROTOC 200 Operating instructions

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