Teledyne 6700-C Total Organic Carbon Analyzer User manual

Teledyne Analytical Instruments

OPERATING INSTRUCTIONS FOR

Model 6700C

High Temperature Combustion

Online TOC Analyzer

DANGER

Depending upon your application, toxic gases may be present in this monitoring

system.

Personal protective equipment may be required when servicing this instrument.

Hazardous voltages exist on certain components internally which may persist

for a time even after the power is turned off and disconnected.

Only authorized personnel should conduct maintenance and/or servicing.

Before conducting any maintenance or servicing, consult with authorized

supervisor/manager.

P/N M6700C-C

3/06/12

Model 6700C TOC

Teledyne Analytical Instruments ii

stored in a retrieval system, or translated into any other language or computer language in

whole or in part, in any form or by any means, whether it be electronic, mechanical,

magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne

Instruments/ Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-

1580.

Warranty

This equipment is sold subject to the mutual agreement that it is warranted by us free from

defects of material and of construction, and that our liability shall be limited to replacing or

repairing at our factory (without charge, except for transportation), or at customer plant at

our option, any material or construction in which defects become apparent within one year

from the date of shipment, except in cases where quotations or acknowledgements provide

for a shorter period. Components manufactured by others bear the warranty of their

manufacturer. This warranty does not cover defects caused by wear, accident, misuse,

neglect or repairs other than those performed by TI/AI or an authorized service center. We

assume no liability for direct or indirect damages of any kind and the purchaser by the

acceptance of the equipment will assume all liability for any damage which may result from

its use or misuse.

We reserve the right to employ any suitable material in the manufacture of our apparatus,

and to make any alterations in the dimensions, shape or weight of any parts, in so far as

such alterations do not adversely affect our warranty.

Important Notice

This instrument provides measurement readings to its user, and serves as a tool by which

valuable data can be gathered. The information provided by the instrument may assist the user

in eliminating potential hazards caused by his process; however, it is essential that all

personnel involved in the use of the instrument or its interface, with the process being

measured, be properly trained in the process itself, as well as all instrumentation related to it.

The safety of personnel is ultimately the responsibility of those who control process

conditions. While this instrument may be able to provide early warning of imminent

danger, it has no control over process conditions, and it can be misused. In particular, any

alarm or control systems installed must be tested and understood, both as to how they

operate and as to how they can be defeated. Any safeguards required such as locks, labels,

or redundancy, must be provided by the user or specifically requested of TI/AI at the time

the order is placed.

Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser

is responsible for the training of personnel, for providing hazard warning methods and

instrumentation per the appropriate standards, and for ensuring that hazard warning devices

and instrumentation are maintained and operated properly.

Teledyne Instruments/Analytical Instruments, the manufacturer of this instrument, cannot

accept responsibility for conditions beyond its knowledge and control. No statement

expressed or implied by this document or any information disseminated by the

manufacturer or its agents, is to be construed as a warranty of adequate safety control under

the user’s process conditions.

High Temperature Combustion

Teledyne Analytical Instruments iii

Specific Model Information

Instrument Serial Number: _______________________

Instrument Range: _______________

Zero Gas: _______________

Span Gas: _______________

Model 6700C TOC

Teledyne Analytical Instruments iv

Safety Messages

Your safety and the safety of others is very important. We have

provided many important safety messages in this manual. Please read

these messages carefully.

A safety message alerts you to potential hazards that could hurt you

or others. Each safety message is associated with a safety alert symbol.

These symbols are found in the manual and inside the instrument. The

definition of these symbols is described below:

GENERAL WARNING/CAUTION: Refer to the instructions

for details on the specific danger. These cautions warn of

specific procedures which if not followed could cause bodily

Injury and/or damage the instrument.

WARNING: HOT SURFACE WARNING: This warning is

specific to heated components within the instrument. Failure

to heed the warning could result in serious burns to skin and

underlying tissue.

WARNING: ELECTRICAL SHOCK HAZARD: Dangerous

voltages appear within this instrument. This warning is

specific to an electrical hazard existing at or nearby the

component or procedure under discussion. Failure to heed this

warning could result in injury and/or death from

electrocution.

Technician Symbol: All operations marked with this symbol

are to be performed by qualified maintenance personnel only.

CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE

PURPOSE AND IN THE MANNER DESCRIBED IN

THIS MANUAL.

IF YOU USE THE ANALYZER IN A MANNER OTHER

THAN THAT FOR WHICH IT WAS INTENDED,

UNPREDICTABLE BEHAVIOR COULD RESULT

POSSIBLY ACCOMPANIED WITH HAZARDOUS

CONSEQUENCES.

High Temperature Combustion

Teledyne Analytical Instruments v

This manual provides information designed to guide you through

the installation, calibration operation and maintenance of your new

analyzer. Please read this manual and keep it available.

Occasionally, some instruments are customized for a particular

application or features and/or options added per customer requests.

Please check the front of this manual for any additional information in

the form of an Addendum which discusses specific information,

procedures, cautions and warnings that may be peculiar to your

instrument.

Manuals do get lost. Additional manuals can be obtained from

TI/AI at the address given in the Appendix. Some of our manuals are

available in electronic form via the internet. Please visit our website at:

www.teledyne-ai.com.

Model 6700C TOC

Teledyne Analytical Instruments vi

High Temperature Combustion

Teledyne Analytical Instruments vii

Additional Safety Information

All relevant precautions and safety remarks of the gas supplier must be

observed:

General Safety Rules

Legally Binding Safety Rules

In addition to safety rules outlined in this manual, all current

environmental, technical, legal, and governmental regulation must be

adhered to.

General Inspection Requirements

General inspection of the Analyzer must be performed by a trained

technician after each incidence of maintenance, repair, or service.

Power Connections

The Analyzer may only be installed and connected to a main power

supply according to the installation instructions provided in this manual.

All power lines to the Analyzer must have switches to cut off the

electricity.

Spare Parts

Only options and parts specified by TAI may be used in performing

maintenance or repair of the Analyzer.

Modifications and Alternations

Any modifications to the Analyzer or any of its options or parts must

first be authorized by TAI.

Responsibilities & Duties of the Supplier

The supplier is responsible for the safety of the product. However, such

safety can only be reasonably guaranteed if the end user of the product

adheres to the requirements and instructions stipulated in this manual.

Model 6700C TOC

Teledyne Analytical Instruments viii

Responsibilities & Duties of the End User

The end user is responsible to ensure that only trained, authorized

personnel operate and maintain the Analyzer. The end user is

responsible for self-training by reading and adhering to the instructions

in this manual.

Instruction of Dangers

The end user is responsible to ensure that all personnel who operate and

maintain the Analyzer are thoroughly instructed in its proper usage and

have received knowledge of all safety precautions.

Care & Maintenance

The end user is responsible to observe the recommended maintenance

schedule.

Observation & Information

The end user is responsible to immediately inform the supplier if any

additional risks, not addressed in this manual, are discovered.

High Temperature Combustion

Teledyne Analytical Instruments ix

Table of Contents

Additional Safety Information .................................................... vii

List of Figures ............................................................................... xi

List of Tables ............................................................................... xii

Introduction ................................................................................. 15

1.1 Overview 15

Operational Theory ..................................................................... 17

2.1 Measurement Principle 17

Installation and Startup ............................................................... 19

3.1 Installation 19

3.2 Non – Catalytic Reactor Packing 20

3.2.1 Identify Parts 20

3.2.2 Preparation of Combustion Reactor 22

3.2.2.1 Install Quartz Sleeve (Insert) 23

3.2.2.2 Loading Ceramic Wool Slices 23

3.3 Catalytic Reactor Packing 24

3.4 Inserting Reactor into Furnace 25

3.5 Startup of the Analyzer 27

3.6 Shutdown 28

Operation ..................................................................................... 29

4.1 Menus 29

4.2 Run Mode 29

4.3 Edit 30

4.3.1 Edit/Parameters 31

4.3.2 Edit/Alarms 32

4.4 Cal 32

4.4.1 Organic and Inorganic Carbon Standards 32

Model 6700C TOC

Teledyne Analytical Instruments x

4.4.2 Reagents 34

4.4.2.1 Preparation Of Sulfuric Acid Solution 34

4.4.3 NDIR Calibration (Gas Calibration) 34

4.4.4.“End-to End” Calibration 36

4.5 Chart 37

4.5.1 Scale 38

4.5.2 Last 24 Hours 38

4.5.3 Historical Data 39

4.6 Test 39

Maintenance ................................................................................ 41

5.1 Factory Assistance 41

5.2 Troubleshooting Guide 41

5.3 Module Service 42

5.3.1 NDIR Calibration 42

5.3.2 NDIR Service 42

5.3.3 Master Interface Board 47

5.3.4 D.C. Power Supply 47

5.3.5 Computer 48

5.3.6 Reactor Assembly and Gas/Liquid Separator 49

5.3.7 Mass Flow Controller 51

5.3.8 Metering Valve 52

5.3.9 Sparger 53

5.3.10 Injector Assembly 54

Appendix ...................................................................................... 57

A.1 Specifications 57

A-2 Recommended Spare Parts 58

High Temperature Combustion

Teledyne Analytical Instruments xi

List of Figures

Figure 2-1 Typical Flow Diagram ................................................... 18

Figure 3-1: Combustion Module Interior ........................................ 20

Figure 3-2: Installing Quartz Insert into Reactor ............................ 23

Figure 3-4: Catalyst Packing ......................................................... 24

Figure 3-5: Gas/Liquid Separator .................................................. 25

Figure 3-6: Filling Separator with DI Water .................................... 26

Figure 3-7: Attaching Reactor Top ................................................ 26

Figure 3-8: Top Retainer Installation ............................................. 27

Figure 4-1: Connecting Calibration Adapter .................................. 35

Figure 5-1: Removing the NDIR .................................................... 43

Figure 5-2: Removing the Master Interface Board Assembly ........ 47

Figure 5-3: DC Power Supply ........................................................ 48

Figure 5-4: Removing Computer Module ...................................... 49

Figure 5-5: Reactor Assembly and GLS ........................................ 50

Figure 5-6: Typical Mass Flow Controller ..................................... 51

Figure 5-7: Metering Valve ............................................................ 52

Figure 5-8: Sparger ....................................................................... 53

Figure 5-9: Injector Assembly ........................................................ 55

Model 6700C TOC

Teledyne Analytical Instruments xii

List of Tables

Table 3-1: Preparation of Standards (TOC) .................................. 33

Table 3-2: Preparation of Standards (TN) ..................................... 33

Table 3-3: Preparation of Standards (TIC) .................................... 33

Table 5-1 Troubleshooting ............................................................ 42

High Temperature Combustion

Teledyne Analytical Instruments xiii

DANGER

COMBUSTIBLE GAS USAGE

WARNING

This is a general purpose instrument designed for use in a

non-hazardous area. It is the customer's responsibility to

ensure safety especially when combustible gases are being

analyzed since the potential of gas leaks always exist.

The customer should ensure that the principles of operating

this equipment are well understood by the user. Misuse of

this product in any manner, tampering with its components,

or unauthorized substitution of any component may

adversely affect the safety of this instrument.

Since the use of this instrument is beyond the control of

Teledyne Analytical Instruments, referred as TAI, no

responsibility by TAI, its affiliates, and agents for damage or

injury from misuse or neglect of this equipment is implied or

assumed.

High Temperature Combustion Operational Theory

Teledyne Analytical Instruments 15

Introduction

1.1 Overview

Teledyne Analytical Instruments (TAI) offers a variety of Total

Organic Carbon (TOC) analyzers to serve a wide range of applications.

The Model 6700C High Temperature Combustion TOC Analyzer

provides accurate and reliable on-line TOC and TN analysis and is

configured to provide maximum utility using an advanced Microsoft

Windows



based CE computer with touch screen.

This manual includes all necessary information to help you install,

operate and service your Analyzer. The analyzer is designed for easy

Operator Maintenance and does not normally require field service.

The Windows-based CE operator interface provides easy, fast and

reliable analysis. This manual includes all necessary information to help

you install, operate and service your Analyzer.

The Model 6700C TOC-True Analyzer is designed for easy

operation and maintenance. Particular attention has been devoted to the

design, whereby any module can be replaced by the operator within 15

minutes. Components such as the NDIR units have been specifically

designed with no moving parts and use a corrosion resistant design to

further reduce maintenance tasks.

The analyzer is suitable for both General Purpose and/or Hazardous

Area classifications, if properly configured with required safety

equipment.

Operating the analyzer is easy. It uses a standard, industrial

Windows



CE computer programmed for complete automatic control

(there are no operator manual adjustments). Operators are advised to

study pertinent chapters in this manual to fully utilize the capabilities of

the analyzer and avoid problems that could be associated with any

instrument.

Operational Theory Model 6700C TOC

Teledyne Analytical Instruments 16

The Analyzer is designed for monitoring of Total Organic Carbon

(TOC) in water. This intended use involves carefully following the

instructions provided in this manual and observing all indicated

warnings, hints and instructions.

High Temperature Combustion Operational Theory

Teledyne Analytical Instruments 17

Operational Theory

2.1 Measurement Principle

Refer to Figure 2-1.

The Injector is connected with all possible flow paths and separated

from sample and reagent liquids by a 10 ml volume loop. One end of the

volume loop is connected to the injector, the other is connected to the

center port of a 10 port Rotary Valve.

A typical sequence of events for the injection unit for measurement

of TOC is as follows:

The Rotary Valve will be engaged, opening a flow path to the drain

line of the analyzer. The Injector is then sent to the home or empty

position.

The DI Valve is turned on and a small amount of DI is then picked

up by the Injector. The DI Valve is then turned off and the Rotary Valve

is turned to the Acid Port where the Injector pulls a small amount of acid

into the loop. The Rotary Valve is then turned to the sample port and

sample is pulled into the loop. The Rotary Valve is turned to the Sparge

Port and the Injector then pushes the sample and acid to the sparger

through the Sparger Port, where the pH is lowered to approximately 2.0

and inorganic carbon is removed.

After the sparge time is completed, the Injector pulls the inorganic

free sample volume from the sparger. The Rotary Valve is then turned to

the Reactor Port. The Injector pumps the sample into the reactor at a

flow rate of one (1) drop in approximately seven (7) seconds.

The sample is oxidized in the High Temperature Furnace where

organic carbon is converted to CO

2

and the gases are directed to a cooler

condenser where excess water is removed, and then on to the NDIR

where the CO

2

is measured and TOC is determined. The gases are then

passed to vent.

Operational Theory Model 6700C TOC

Teledyne Analytical Instruments 18

Figure 2-1 Typical Flow Diagram

High Temperature Combustion Installation/Startup

Teledyne Analytical Instruments 19

Installation and Startup

The Model 6700C is often configured for a specific application as

requested by the customer. Optional equipment and any application

specific configuration of this instrument will be described in an

addendum to this manual. Please check the front of this manual for any

addenda that may be included.

3.1 Installation

Installation of the Total Organic Analyzer includes:

1. Unpacking

2. Mounting

3. Gas Connections

4. Electrical Connections

5. Testing the System

6. Unpacking the Analyzer

The analyzer is shipped with all the materials you need to install

and prepare the system for operation. Carefully unpack the analyzer and

inspect it for damage and immediately report any damage to the

shipping agent.

Note: If the Reactor has been packed and shipped separately,

please follow the instructions below to properly prepare

and install the Reactor.

Open the door of the Combustion Module. Figure 3-1 shows the

reactor properly installed in the furnace.

Teledyne 6700-C Total Organic Carbon Analyzer User manual

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