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Endress+Hauser TOCII CA72TOC Operating Instructions Manual

Analyzer for online determination of toc in aqueous media using thermic catalytic combustion
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Operating Instructions
TOCII CA72TOC
Analyzer for online determination of TOC in aqueous media
using thermic catalytic combustion
BA448C/07/en/06.10
71118197

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Summary of Contents for Endress+Hauser TOCII CA72TOC

  • Page 1 Operating Instructions TOCII CA72TOC Analyzer for online determination of TOC in aqueous media using thermic catalytic combustion BA448C/07/en/06.10 71118197...
  • Page 2 Endress+Hauser...

  • Page 3: Table Of Contents

    TOCII CA72TOC Table of contents Safety instructions ....5 Commissioning ....32 Designated use .
  • Page 4 TOCII CA72TOC Maintenance ....55 Cleaning the housing ..... . . 59 Visual inspection .

  • Page 5: Safety Instructions

    TOCII CA72TOC Safety instructions Safety instructions 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) •...

  • Page 6: Return

    Safety instructions TOCII CA72TOC 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.

  • Page 7: Identification

    TOCII CA72TOC Identification Identification 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 •...

  • Page 8: Scope Of Delivery

    Identification TOCII CA72TOC Carrying gas (optinal, select one option only) -scrubber -scrubber + compressor Analyzer mounting (optinal, select one option only) Wall mounted Stand Accessory mounted (optinal, multiple selection possible) Sample predilution Heated salt trap Pipe back flushing Standby mode PA-2/-3 failure...

  • Page 9: Installation

    TOCII CA72TOC Installation Installation 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.

  • Page 10: Installation Conditions

    Installation TOCII CA72TOC 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 (option F2) 785 (30.9) 400 (15.8)

  • Page 11: Compressed Air And Water Supply

    TOCII CA72TOC Installation 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 CO •...

  • Page 12: Installation Instructions

    Installation TOCII CA72TOC 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.

  • Page 13: Mounting On A Base Frame

    TOCII CA72TOC Installation 3.3.3 Mounting on a base frame In the "Base frame" version, the analyzer is mounted on a base frame. mm (inch) a0013913 Fig. 3: Mounting on a base frame 3.3.4 Connecting the media a0012643 Fig. 4: Connections on the left side panel...
  • Page 14 Installation TOCII CA72TOC Sample supply Sample is supplied via a 3/8" connection on the left side panel (item 11). Sample supply Inlet (mm / inch) Outlet (mm / inch) 40 / 1.57 50 / 1.97 20 / 0.79 32 / 1.26 20 / 0.79...

  • Page 15: Preparing The Chemicals

    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). Specifying the standard concentrations The right choice of standard concentration is key to the accuracy of the measurement method.
  • Page 16 Installation TOCII CA72TOC 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.
  • Page 17 TOCII CA72TOC Installation 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 H (4molar) (CAS: 7664-93-9) and top up the mixture with water until the 1-liter mark is reached.
  • Page 18 Installation TOCII CA72TOC 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.

  • Page 19: Post-Installation Check

    TOCII CA72TOC Installation 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.

  • Page 20: Wiring

    Wiring TOCII CA72TOC Wiring Electrical connection Inappropriate connection can cause serious injuries or death 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. Prior to beginning make sure voltage is not applied to any of the cables.

  • Page 21: Power Distribution

    TOCII CA72TOC Wiring 4.1.2 Power distribution a0011954-en Fig. 5: Power distribution wiring diagram Endress+Hauser...
  • Page 22 Wiring TOCII CA72TOC Terminal strip assignment: Terminal Description Main switch, power distribution Solenoid valve 3 - stripping gas Tube furnace regulator Peltier cooler regulator Membrane compressor Heated salt trap regulator Solenoid valve 4, standard 1 + 2 Solenoid valve 7, carrier gas...

  • Page 23: Signal Connection

    0 to 20 mA or 4 to 20 mA can be switched, galvanically isolated, max. load 500 Ω 24 V DC active, max. load 500 Ω Signal inputs 1 to 8 Note! TOCII CA72TOC is suitable for connection to industrial mains support according to EN 61326-1, class A. Endress+Hauser...

  • Page 24: Power Unit

    Wiring TOCII CA72TOC 4.1.4 Power unit a0011956 Fig. 7: Power unit assignment Power unit wiring arrangement: Connection Description Pump control 24 V DC Magnetic stirrer control 24 V DC Motor Relay module 24 V DC Ventilator 24 V DC The connections for the power unit are located on the rear side of the computer.

  • Page 25: Distributor Connection

    TOCII CA72TOC Wiring 4.1.5 Distributor connection CPU L1 CPU L1 I/O L1 I/O L1 a0011955 Fig. 8: Distributor Distributor assignment Terminal Description IR detector FI 2 Temperature amplifier FI 3 pH amplifier FI 4 Pressure sensor FI 5 pressure switch DI 8...

  • Page 26: Post-Connection Check

    Wiring TOCII CA72TOC Post-connection check Carry out the following checks after electrical connection: Device status and specifications Note Is the exterior of the analyzer or cable undamaged? Visual inspection Electrical connection Note Does the supply voltage correspond to the data on the nameplate?

  • Page 27: Operation

    TOCII CA72TOC Operation Operation Operating elements a0011861 Fig. 9: Display and operating elements Main switch Acid hose connector Display and operating elements MV4 calibration standard changeover C1/C2 Pump P2 sample analysis Valve for online sample/manual sample Junction box MV1 wastewater/calibration standard...

  • Page 28: Display And Keypad

    Operation TOCII CA72TOC Display and keypad a0007996 Fig. 10: Display and operating elements Diaplay, 16 rows a 40 characters Keyboard Arrow keys (cursors) Function key"Measuring" Function key "Service" Function key "Programming" Function key "Help" Key "Enter" Key "Clear" "Operation" key Pressing the "Operation key"...
  • Page 29 TOCII CA72TOC Operation "Enter" key The "Enter key" has the following functions: • You launch a menu item. • You start a program item. • You always confirm an entry with the "Enter key". • When performing maintenance and service tasks, you confirm each step with the "Enter key"...

  • Page 30: Operation During Measuring Mode

    Operation TOCII CA72TOC Operation during measuring mode The analyzer has three operating modes: • Measuring mode • Service mode • Programming mode The measuring mode is fully automated. Manual intervention on the part of the user is not possible. 11:39:04...

  • Page 31: Standby Mode

    TOCII CA72TOC Operation 1000 RECORD VALUE= 238 mg/l DATE 08/29/08 TIME= 8:30 a0012449-en Fig. 12: Spot view (example) Time mark on the load curve Measured value of the selected time 1 hour earlier 2 minutes earlier 1 hour later 2 minutes later You can switch the spot view (cursor) off with the Enter key.

  • Page 32: Commissioning

    Commissioning TOCII CA72TOC Commissioning Function check Warning! • Check all connections for correctness. • Make sure that the supply voltage is identical to the voltage indicated on the nameplate! Start 6.2.1 Commissioning sequence Preparation: Install the pH sensor in the strip chamber and connect the sensor cable to the amplifier.

  • Page 33: Clr Start

    TOCII CA72TOC Commissioning 6.2.2 CLR start You must perform a CLR start the first time you put your analyzer into operation. This loads the analyzer software and deletes all the previous data saved. The parameters remain. Perform a CLR start as follows: Press and hold down the CLR key for approx.

  • Page 34: Programming Mode

    Commissioning TOCII CA72TOC Programming mode You configure the operating parameters of the analyzer in the programming mode. Press the programming key. Enter the "code". The code is a four-digit number which you can find on the code card supplied with your analyzer.

  • Page 35: Menu Setting - Range Data

    TOCII CA72TOC Commissioning 6.3.1 Menu SETTING - RANGE DATA P R O G R A M M I N G RANGE DATA SETTING SET CLOCK LISTS ALARM LIMITS BASIC DATA TEST SET DEFAULTS MEASURING SITE a0012553-en Fig. 15: Menu "Setting"...

  • Page 36: Menu Setting - Set Clock

    Commissioning TOCII CA72TOC 6.3.2 Menu SETTING - SET CLOCK This section describes how you enter the date and the time. Select the programming mode for this purpose. Step Display Description P R O G R A M M I N G...

  • Page 37: Menu Setting - Basic Data

    TOCII CA72TOC Commissioning 6.3.4 Menu SETTING - BASIC DATA P R O G R A M M I N G SETTING RANGE DATA SET CLOCK LISTS ALARM LIMITS BASIC DATA TEST SET DEFAULTS MEASURING SITE a0012580-en Fig. 17: "Programming" menu...

  • Page 38: Menu Setting - Set Defaults

    Commissioning TOCII CA72TOC 6.3.5 Menu SETTING - SET DEFAULTS Step Display Description P R O G R A M M I N G SETTING RANGE DATA SET CLOCK LISTS ALARM LIMITS BASIC DATA TEST SET DEFAULTS MEASURING SITE • If you are sure that you want to reset to SET DEFAULTS the factory settings, press the [E] key.

  • Page 39: Menu Lists - Maintenance Record

    TOCII CA72TOC Commissioning 6.3.8 Menu LISTS - MAINTENANCE RECORD P R O G R A M M I N G SETTING LISTS MAX MIN AVERAGE MAINTENANCE RECORD TEST ALARM RECORD SHOW COMPLETE RECORDS a0012586-en Fig. 20: "Lists" menu All the maintenance procedures are recorded by maintenance activity in the maintenance record.

  • Page 40: Menu Lists - Alarm Record

    Commissioning TOCII CA72TOC Action Description REPLACE GAS FILTERS Date and time when selected in the service menu REPLACE O2 FILTER Date and time when selected in the service menu HEATED FILTER Date and time when selected in the service menu (optionally heated salt trap)
  • Page 41 TOCII CA72TOC Commissioning Alarm Description POWER FAILURE Power supply failure POWER ON Power is reestablished ALARM T<Tmin Furnace temperature drops below 85 % of the set value Operation stops. System starts as soon as 90 % of the set value is reached.

  • Page 42: Records

    Commissioning TOCII CA72TOC 6.3.10 Menu LISTS - SHOW COMPLETE RECORDS P R O G R A M M I N G SETTING LISTS MAX MIN AVERAGE MAINTENANCE RECORD TEST ALARM RECORD SHOW COMPLETE RECORDS a0012588-en Fig. 23: "Lists" menu Chronological display of all the events saved. The last 200 events are saved in the complete record list.
  • Page 43 TOCII CA72TOC Commissioning Step Display Description Analog inputs xxx.xx xxxx Hz • Current CO measured value °C xxxx Hz • Furnace temperature • Pressure level in gas circuit mbar xxxx Hz • pH value in stripping vessel xxxx Hz x.xx...

  • Page 44: Menu Test - Test Of Outputs

    Commissioning TOCII CA72TOC 6.3.12 Menu TEST - TEST OF OUTPUTS Step Display Description P R O G R A M M I N G SETTING LISTS TEST TEST OF INPUTS TEST OF OUTPUTS TEST FREQUENCY I/O TEST COM2 MEASUREMENT OFF 1.

  • Page 45: Menu Test - Test Frequency I/O

    TOCII CA72TOC Commissioning Output Description Switch status OFF Switch status ON Changeover between standard and sample Sample Standard solution Flushing valve for power flushing Strip chamber flushing Strip chamber flushing switched off switched on supply, tube furnace controller, Peltier Consumer load switched off...

  • Page 46: Menu Test - Measurement Off

    Commissioning TOCII CA72TOC 6.3.15 Menu TEST - MEASUREMENT OFF P R O G R A M M I N G SETTING LISTS TEST TEST OF INPUTS TEST OF OUTPUTS TEST FREQUENCY I/O TEST COM2 MEASUREMENT OFF a0012618-en Fig. 27: "Test" menu Deactivates measuring operation.
  • Page 47 TOCII CA72TOC Commissioning Settings for the analog outputs You must enter the following parameters in the Basic Data menu: PROGRAMMING/SETTING/BASIC DATA: Parameter Unit Description SCALE AO CH1 Scale end value of the analog output of channel 1. SCALE AO CH2 Scale end value of the analog output of channel 2.

  • Page 48: Two-Channel: Time-Controlled Changeover

    Commissioning TOCII CA72TOC 6.3.17 Two-channel: time-controlled changeover The analyzer is equipped with two separate sample supply systems. Setting of the measurement duration The measurement duration can be set indivually for each channel. PROGRAMMING/SETTING/BASIC DATA: Parameter Unit Description DURATION K1 Measurement duration for channel 1...
  • Page 49 TOCII CA72TOC Commissioning Parameter Unit Description HI ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value for channel 1 is overshot. LO ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value for channel 1 is undershot.

  • Page 50: Optimizing The Analyzer

    The measuring range is altered by changing a component: • By changing the infrared detector (Endress+Hauser Service) • By fitting a predilution system (Endress+Hauser Service) In terms of device settings, the feed rate of dosing pump P2 is optimized.

  • Page 51: Operating The Analyzer With High Salt

    If the reduction in pump P2 dosing does not have the desired effect, the salt load can be minimized via optional upstream dilution of the sample (Endress+Hauser Service). Dilution ratios between 1:5 to 1:20 are possible. The effective TOC concentration in the diluted wastewater should be inside the measuring range of the analyzer.

  • Page 52: Communication

    Commissioning TOCII CA72TOC Communication The analyzer is equipped with an RS-232 serial interface. Data transmission is unidirectional and is performed with the following parameters: Baud rate 9600 baud Bits 8 bit Parity Stop bit 1 bit Handshake The string is 104 bytes long and is sent every 2 seconds.
  • Page 53 TOCII CA72TOC Commissioning Byte Description Gas circuit pressure monitoring 0 = OK 1 = 70 % of max. permitted pressure 2 = > max. permitted pressure Check CO basic line (0 = off, 1 = on) Adjustment error (0 = off, 1 = on)
  • Page 54 Commissioning TOCII CA72TOC Byte Description Separator 48 to 53 (ppm) 1 decimal place; current value of the gas card Separator 55 to 60 (ppm) 1 decimal place; CO difference calculated from the measuring cycle Separator 62 to 67 pH value...

  • Page 55: Maintenance

    TOCII CA72TOC Maintenance Maintenance Maintenance work has to be performed at regular intervals to ensure the efficient operation of the analyzer. Warning! Before attempting to service the device, you must be completely familiar with the maintenance processes and have perfectly understood the tasks involved. All the maintenance tasks described in this chapter should only be carried out by suitably trained specialists.
  • Page 56 Maintenance TOCII CA72TOC Flow chart Use this chart as reference if you have to replace or reconnect pipes or tubes. a0012369-en Fig. 28: Flow chart Endress+Hauser...
  • Page 57 TOCII CA72TOC Maintenance Interior views a0011861 Fig. 29: Display and operating elements Main switch Acid hose connector Display and operating elements MV4 calibration standard changeover C1/C2 Pump P2 sample analysis Valve for online sample/manual sample Junction box MV1 wastewater/calibration standard changeo-...
  • Page 58 Maintenance TOCII CA72TOC a0012022 Fig. 30: Rear of device Leak detector contacts pH - amplifier Peltier cooler Carrier gas dosing valve Peltier cooler - glass insert Stripping gas dosing valve Heating regulator - heatable salt trap MV7 carrier gas flushing...

  • Page 59: Cleaning The Housing

    TOCII CA72TOC Maintenance Cleaning the housing " Caution! When cleaning, make sure you do not damage the nameplate on the analyzer! Do not use cleaning agents containing solvents! Clean the analyzer housing as follows: • Use fluoride-free cleaner and a lint-free cloth.

  • Page 60: Topping Up Reagents

    Maintenance TOCII CA72TOC Topping up reagents Warning! • When working with reagents, always observe the warnings on the safety data sheets. • Wear acid-resistant protective gloves, protective goggles and a protective laboratory coat! • In addition, adhere to the regulations applicable in your country and to your line of work governing the handling of caustic chemicals.

  • Page 61: Topping Up Or Replacing The Standard

    TOCII CA72TOC Maintenance Topping up or replacing the standard This section describes how the standard solutions are replaced. Step Display Description BYPASS SCREEN stops the measuring S E R V I C E operation. PUMPS CALIBRATION CLEANING SCREEN FLUSH POWER-FLUSH...

  • Page 62: Entering The Concentration Of The Standard Solution

    Maintenance TOCII CA72TOC Entering the concentration of the standard solution This section describes how the concentration of the standard solution is entered. Select the programming mode for this purpose: Step Display Description P R O G R A M M I N G...

  • Page 63: Pumps

    TOCII CA72TOC Maintenance Pumps 7.7.1 Replacing the hoses on pumps P1 and P4 This section describes how the hoses of pumps P1 and P4 are replaced and the delivery rate is determined. Warning! Danger of crushing! Never reach into the pump head while the pump is in operation! a0012483 Fig.
  • Page 64 Maintenance TOCII CA72TOC a0012364 Fig. 34: Pump P1 Pump retainer Motor Pump head Condensate hose (BK-BK) 0.76 mm (0.03") ID Hose cassette (sample hose) Sample hose (VT-WH) 2.79 mm (0.11") ID Hose cassette (condensate hose) Adjusting screw Pump P1: Sample hose to strip chamber has an ID of 2.79 mm (0.11") and the color code violet-white (VT-WH).
  • Page 65 TOCII CA72TOC Maintenance Step Display Description 1. Set the sample valve to manual REPLACE HOSE P1/4 sampling. 2. To empty the pump hose and the strip chamber, place a collecting vessel under the hose connection for SWITCH VALVE TO MANUAL SAMPLING, manual sampling.
  • Page 66 Maintenance TOCII CA72TOC Step Display Description In areas with a low amount of dust: REPLACE HOSE P1/4 Grease the new hoses with a light coating of silicone grease. 1. Hold paper under the strip chamber and mixer hose connection. 2. Release the pump hoses (items 6 + 7) REPLACE PUMP HOSE from the connections.
  • Page 67 TOCII CA72TOC Maintenance Step Display Description You can enter the new value after 60 REPLACE HOSE P1/4 seconds. The value typically lies between 5.5 and 7 ml (0.18 and 0.24 fl.oz). PREVIOUS VOLUME DELIVERED x.x ml ENTER ml? [E] TO CONFIRM...
  • Page 68 Maintenance TOCII CA72TOC Step Display Description 1. Use the dosing nozzle of the injector REPLACE HOSE P1/4 to expand the hose end of the condensate hose. 2. Connect the suction side of the condensate hose and place the pressure side of the condensate hose into a glass containing water.
  • Page 69 TOCII CA72TOC Maintenance Step Display Description Press the [E] key. REPLACE HOSE P1/4 NEW VOLUME DELIVERED x.x ml [>] START/STOP PUMP 1 (60sec) [E] TO CONFIRM 1. Connect hose P1 at the pressure side. REPLACE HOSE P1/4 2. Press the [E] key.
  • Page 70 Maintenance TOCII CA72TOC Step Display Description For version "without predilution": 1. Lock the hose cassettes in place in the retainer. REPLACE HOSE P1/4 2. Make sure the hose cassette is seated correctly in the retainer. 3. Use the dosing nozzle of the injector to expand the hose end of the condensate hose.
  • Page 71 TOCII CA72TOC Maintenance Step Display Description Press the [E] key. REPLACE HOSE P1/4 NEW VOLUME DELIVERED x.x ml [>] START/STOP PUMP 1 (60sec) [E] TO CONFIRM 1. Connect hose P1 at the pressure side. REPLACE HOSE P1/4 2. Press the [E] key.

  • Page 72: Replacing The Hose On Pump P2

    Maintenance TOCII CA72TOC 7.7.2 Replacing the hose on pump P2 This section describes how the hose of pump P2 is replaced. The following service menus are automatically started when this service menu finishes: Adjusting pump P2 Empty volume dosing Warning!
  • Page 73 TOCII CA72TOC Maintenance a0014230 Fig. 36: Pump P2 Pump retainer Adjusting screw Pump head Hose cassette Sample hose (BK-BK) 0.76 mm (0.03") ID Motor Pump P2: Pumps sample from the separation chamber into the furnace. Hose: (BK-BK) 0.76 mm (0.03")
  • Page 74 Maintenance TOCII CA72TOC Step Display Description The hose is drained automatically. REPLACE HOSE P2 PLEASE WAIT PUMP CONVEYS BACKWARDS [E] TO CONFIRM 1. Open the cover of the separation REPLACE HOSE P2 chamber. 2. Empty the separation chamber with the syringe (part of the scope of supply).

  • Page 75: Replacing The Hose On Pump P3

    TOCII CA72TOC Maintenance Note! The accuracy of the feed rate of pump P2 affects the measurement result. For this reason, the following service menus are started in the order indicated once the pump hose has been replaced: "Adjust pump 2"...
  • Page 76 Maintenance TOCII CA72TOC a0012368 Fig. 38: Pump P3 Pump retainer Motor Pump head Acid hose (BK-BK) 0.76 mm (0.03") ID Hose cassette Adjusting screw Pump P3: Pumps acid from the feeder tank into the strip chamber. Hose: (BK-BK) 0.76 mm (0.03")
  • Page 77 TOCII CA72TOC Maintenance Step Display Description 1. Release the hose connection from REPLACE HOSE P3 pump P1 to the strip chamber. 2. Have a vessel at the ready to collect EMPTY STRIP CHAMBER BY the liquid. DISCONNECTING HOSE CONNECTION OF SAMPLE PUMP P1 AT THE STRIP CHAMBER 3.
  • Page 78 Maintenance TOCII CA72TOC Step Display Description 1. Rinse the suction hose of the acid REPLACE HOSE P3 pump. 2. Guide the suction tube into the acid feeder tank. INSERT ACID SUCT. HOSE IN ACID FEEDER; INSERT HOSE CASSETTE IN P3 3.

  • Page 79: Adjusting Pump P2

    TOCII CA72TOC Maintenance 7.7.4 Adjusting pump P2 This section describes how the feed rate of pump P2 is determined. The "Empty volume dosing" service menu is started automatically when this service menu finishes: Warning! Danger of crushing! Never reach into the pump head while the pump is in operation! a0012484 Fig.
  • Page 80 Maintenance TOCII CA72TOC Step Display Description S E R V I C E PUMPS P 1/4 REPLACE HOSE PUMP 2 REPLACE HOSE CALIBRATION PUMP 3 REPLACE HOSE CALIBRATE PUMP 2 CLEANING FILTERS Warning! CALIBRATE PUMP 2 There is a risk of infection when working...
  • Page 81 TOCII CA72TOC Maintenance Step Display Description CALIBRATE PUMP 2 1. Place a graduated beaker underneath the end of the dosing tube. 2. Press the [E] key to start time-controlled dosage. MEASURING VESSEL READY ? [E] TO CONFIRM Pump P2 pumps at 100 % for 10 minutes.

  • Page 82: Cleaning Dilution Water Pump P5

    If you use deionized water as the dilution medium, pump P5 only has to be cleaned as part of the annual maintenance work performed by Endress+Hauser Service. The maintenance intervals can be shorter if you use drinking water as the dilution medium.
  • Page 83 TOCII CA72TOC Maintenance Disassembling pump P5 Depressurize the water supply. Switch off the power supply and afterwards disconnect the plug of pump P5 from the pump control system. Switch the power supply back on again (the furnace should not cool down).

  • Page 84: Calibration

    Maintenance TOCII CA72TOC Calibration 7.8.1 Adjusting the analyzer This section describes how the analyzer is adjusted. The analyzer is adjusted using two-point adjustment. Two different standard solutions are measured for this purpose. These standard solutions are connected in the analyzer.
  • Page 85 TOCII CA72TOC Maintenance Manually activated adjustment Step Display Description S E R V I C E PUMPS CALIBRATION ANALYZER ADJUSTMENT ANALYZER CALIBRATION CLEANING EMPTY VOLUME DOSING ADJUSTMENT pH SENSOR FILTERS Remotely activated adjustment Adjustment can be triggered by a floating contact. Use input 2 of the "binary in" terminal strip for this purpose.

  • Page 86: Calibrating The Analyzer

    Maintenance TOCII CA72TOC Automatically activated adjustment The analyzer can be adjusted automatically. Select the programming mode for this purpose: Step Display Description P R O G R A M M I N G RANGE DATA SETTING SET CLOCK LISTS ALARM LIMITS...
  • Page 87 TOCII CA72TOC Maintenance Remotely activated calibration Calibration can be triggered by a floating contact. Use input 1 of the "binary in" terminal strip for this purpose. +24VDC +24VDC +24VDC +24VDC +24VDC +24VDC +24VDC 0/4-20 +24VDC 0/4-20 +24VDC RS 232 RS 232 a0011911 Fig.

  • Page 88: Empty Volume Dosing

    Maintenance TOCII CA72TOC Note! Analog value output during calibration During calibration, the last TOC value is transmitted to the analog output and held until the calibration value has been determined. The calibration value is then transmitted to the analog output (or to analog output channel 1 in the two-channel version) until a new measured value of the current sample is determined.
  • Page 89 TOCII CA72TOC Maintenance Step Display Description The pump pumps automatically in the DETERMINE EMPTY VOLUME DOSING direction of the capillary. Pumping stops if: PUMP CONVEYS SAMPLE FOR INJECTION a) A drop is detected or b) The system times out after 180 s.
  • Page 90 Maintenance TOCII CA72TOC Step Display Description Start the pump with the [E] key. DETERMINE EMPTY VOLUME DOSING PUMP CONVEYS SAMPLE FOR INJECTION WHEN FIRST DROP FALLS AT THE CAPILLARY STOP PUMP! [E] START PUMP Stop the pump with the [E] key when the DETERMINE EMPTY VOLUME DOSING first drop falls.

  • Page 91: Adjusting The Ph Sensor

    TOCII CA72TOC Maintenance 7.8.4 Adjusting the pH sensor This section describes how to remove and install the pH sensor, and how to perform two-point adjustment on the pH sensor. a0012478 Fig. 50: Position of the sensor To adjust the pH sensor, you require: •...
  • Page 92 Maintenance TOCII CA72TOC Step Display Description S E R V I C E PUMPS CALIBRATION ANALYZER ADJUSTMENT ANALYZER CALIBRATION CLEANING EMPTY VOLUME DOSING ADJUSTMENT pH SENSOR FILTERS 1. Release the thread adapter nut (3) on ADJUSTMENT pH SENSOR the strip chamber (4).
  • Page 93 TOCII CA72TOC Maintenance Step Display Description 1. Rinse the sensor with deionized ADJUSTMENT pH SENSOR water. 2. Hold the sensor in the buffer solution pH = 7.00. RINSE SENSOR WITH DI WATER 3. Press the [E] key. PLACE SENSOR INTO SOLUTION pH= 7.00 [E] TO CONFIRM 1.
  • Page 94 Maintenance TOCII CA72TOC Step Display Description The adjustment constants are not ADJUSTMENT pH SENSOR accepted. • Check the buffer solutions. ERROR pH ADJUSTMENT • Check the sensor or • Replace the sensor. SLOPE: xx mV/DECADE Repeat the adjustment. CHECK BUFFER SOLUTION AND SENSOR...

  • Page 95: Cleaning

    TOCII CA72TOC Maintenance Cleaning 7.9.1 Screen flushing During a screen flush, the sample conditioning system and the filter used are flushed with pressurized water. This takes place via solenoid valve MV5. a0012726 Fig. 52: Position of the screen Screen flushing runs automatically after startup, and can be started in three ways: •...

  • Page 96: Power Flush

    Maintenance TOCII CA72TOC 7.9.2 Power flush During a power flush, the strip chamber and separation chamber are flushed with the connected pressurized water via solenoid valve MV2. a0012478 Fig. 53: Position of the strip and separation chamber Power flushing runs automatically after startup, and can be started in three ways: •...

  • Page 97: Bypass Screen

    TOCII CA72TOC Maintenance 7.9.3 Bypass screen This section describes how the bypass screen is cleaned manually. a0012489 Fig. 54: Sample conditioning Upper thread adapter nut Vent Bypass elbow Bypass screen Lower thread adapter nut O-ring Bypass screen housing O-ring You require the following parts: •...
  • Page 98 Maintenance TOCII CA72TOC Step Display Description Warning! BYPASS-SCREEN There is a risk of infection when working with wastewater! For this reason, wear protective goggles, protective gloves and protective clothing. MAINTENANCE COMPLETED ? Clean the bypass screen as follows: 1. Shut off the supply of wastewater (external sample supply).

  • Page 99: Strip And Separation Chamber

    TOCII CA72TOC Maintenance 7.9.4 Strip and separation chamber This section describes how to manually clean the strip and separation chamber and replace the glass bead. a0012478 Fig. 55: Position of the strip and separation chamber You require the following parts: •...
  • Page 100 Maintenance TOCII CA72TOC a0012343 Fig. 56: Strip and separation chamber pH sensor Separation chamber Strip chamber cover Separation chamber cover Strip chamber thread adapter nut Magnetic stir bar Coupling Glass bead Strip chamber Glass frit Coupling (drain) O-ring Separation chamber thread adapter nut...
  • Page 101 TOCII CA72TOC Maintenance Step Display Description Warning! STRIPPER + SEPARATION There is a risk of infection when working with wastewater! For this reason, wear protective goggles, protective gloves and protective clothing. CAUTION! LIQUID CAN LEAK OUT WEAR PROTECTIVE CLOTHES Press the [E] key.
  • Page 102 Maintenance TOCII CA72TOC Step Display Description 7. Use the pliers to remove the magnetic stir bar (item 10) from the separation chamber (item 8). 8. Empty the separation chamber (item 8) with the injector (withdrawn by suction). 9. Connect the empty injector to the suction needle for the sample (connection P2).

  • Page 103: Opening The Circuit

    TOCII CA72TOC Maintenance 7.9.5 Opening the circuit This section describes how the dosing head (capillary) is cleaned or replaced. The furnace temperature is not reduced. The system continues to perform sample conditioning (stripping). a0012498 Fig. 57: Position of the dosing unit You require the following parts: •...
  • Page 104 Maintenance TOCII CA72TOC Step Display Description S E R V I C E PUMPS CALIBRATION CLEANING SCREEN FLUSH POWER-FLUSH FILTERS BYPASS-SCREEN STRIPPER+SEPARATION OPEN GAS CICUIT COMBUSTION PIPE LEAKAGE TEST Clean the needle as follows: OPENING THE GAS CIRCUIT 1. Remove the hose P2 from the capillary of the dosing head.

  • Page 105: Combustion Pipe

    TOCII CA72TOC Maintenance 7.9.6 Combustion pipe This section describes how the combustion pipe is cleaned and replaced, or how the entire furnace is replaced. The furnace heating system is switched off. a0012530 Fig. 59: Position of the furnace You require the following parts: •...
  • Page 106 Maintenance TOCII CA72TOC a0012387 Fig. 60: Furnace Dosing head Knurled head screw Red screw plug Seal Furnace cover Optional heatable salt trap Thread adapter nut Safety guard Furnace outlet Combustion pipe Step Display Description S E R V I C E...
  • Page 107 TOCII CA72TOC Maintenance Step Display Description Warning! COMBUSTION PIPE Use heat-resistant gloves. Contact with hot parts of the combustion furnace may cause injury! The power supply for the combustion REMOVE HOSE P2 FROM FURNACE furnace is switched off. The furnace cools down.
  • Page 108 Maintenance TOCII CA72TOC Step Display Description Only for furnace replacement: Warning! Use heat-resistant gloves. Contact with hot parts of the combustion COMBUSTION PIPE furnace may cause injury! 1. Release the hose connection on the mounting plate or on the heated salt TEMPERATURE °C...
  • Page 109 TOCII CA72TOC Maintenance Step Display Description Reassembling the combustion unit 1. Insert the combustion pipe into the tube furnace. 2. Place the combustion pipe insert with filler (approx. 25 g high-temperature catalyst) into the combustion pipe. 3. Check and clean the support ring and sealing ring for the furnace cover and insert the sealing ring and the support ring.
  • Page 110 Maintenance TOCII CA72TOC Step Display Description 1. Install the hose at the injection unit. COMBUSTION PIPE 2. Check that the hose is correctly inserted in the magnetic valve 8. 3. Press the [E] key. RE-CONNECT HOSE P2 [E] TO CONFIRM...

  • Page 111: Leakage Test

    TOCII CA72TOC Maintenance 7.9.7 Leakage test This section describes how the gas circuit is checked for leaks. Check the leak-tightness of the gas circuit after each modification to the furnace. You require the following parts: • Drain plug from the accessories supplied a0012531 Fig.
  • Page 112 Maintenance TOCII CA72TOC Step Display Description Press the [->] key. LEAKAGE TEST The carrier gas valve is opened and pressure is applied to the gas circuit. The carrier gas valve is closed CARRIER VALVE mbar automatically: • If the pressure has exceeded 100 mbar •...

  • Page 113: Filters

    TOCII CA72TOC Maintenance 7.10 Filters 7.10.1 Replacing the acid filter This section describes how the acid filter is replaced. Replace the acid filter: • If it is blocked or worn out. This is noticeable from the flow rate and pressure level of the gas circuit.
  • Page 114 Maintenance TOCII CA72TOC Step Display Description S E R V I C E PUMPS CALIBRATION CLEANING FILTERS REPLACE ACID FILTER REPLACE GAS FILTERS REPLACE O2 FILTERS REPLACE HEATED FILTER Warning! REPLACE ACID FILTER Wear protective gloves! 1. Release the couplings (items 1 and 2.

  • Page 115: Replacing The Gas Filter

    TOCII CA72TOC Maintenance 7.10.2 Replacing the gas filter This section describes how the gas filter is replaced. Replace the gas filter if it is blocked. a0012500 Fig. 64: Position of the gas filter a0012307 Fig. 65: Gas filter Coupling Gas filter...
  • Page 116 Maintenance TOCII CA72TOC Step Display Description S E R V I C E PUMPS CALIBRATION CLEANING FILTERS REPLACE ACID FILTER REPLACE GAS FILTERS REPLACE O2 FILTERS REPLACE HEATED FILTER 1. Release the couplings (items 1 and REPLACE GAS FILTERS 2. Replace the gas filter (item 2).

  • Page 117: Replacing The O2 Filter

    TOCII CA72TOC Maintenance 7.10.3 Replacing the O filter This section describes how the O filter is replaced. The gas connection block with the O filter is mounted on the rear of the analyzer. You require the following parts: • Open-ended wrench •...
  • Page 118 Maintenance TOCII CA72TOC Step Display Description 1. Release the coupling (item 3). REPLACE O2 FILTER 2. Check the O2 filter (item 2) for possible signs of wear. Replace the filter if necessary. 3. Screw the coupling into the gas MAINTENANCE COMPLETED ? connection block.

  • Page 119: Replacing The Heated Salt Trap

    TOCII CA72TOC Maintenance 7.10.4 Replacing the heated salt trap This section describes how the heated salt trap is replaced. a0012515 Fig. 67: Position of the heated salt trap You require the following parts: • 4 mm Allen key • Deionized water •...
  • Page 120 Maintenance TOCII CA72TOC Note! To ensure that the furnace does not cool down too much during the cleaning process, it is heated between the point the salt trap is removed and the salt trap is installed. Extended measuring device downtime results if the furnace cools down too much, and should therefore be avoided.
  • Page 121 TOCII CA72TOC Maintenance Step Display Description 1. Release the hose on the outlet of the REPLACE HEATED FILTER heated salt trap. 2. Raise the salt trap (item 2) slightly. 3. Fold back the retaining bracket (item TEMPERATURE °C 4. Remove the salt trap (item 2) from below.
  • Page 122 Maintenance TOCII CA72TOC Step Display Description The analyzer waits until 90 % of the set REPLACE HEATED FILTER temperature has been reached. TEMPERATURE °C WAIT UNTIL 90% OF SET TEMP. IS REACHED Press the [E] key to start measuring REPLACE HEATED FILTER operation.

  • Page 123: Accessories

    TOCII CA72TOC Accessories Accessories Reagents • CAY450-V10AAE, 1000 ml stripper reagent für CA72TOC • CAY451-V10C01AAH, 1000 ml parent solution 5 000 mg/l TOC • CAY451-V10C10AAH, 1000 ml parent solution100 000 mg/l TOC Technical buffer solutions, accuracy 0.02 pH, according to NIST/DIN •...

  • Page 124: Troubleshooting

    Troubleshooting TOCII CA72TOC Troubleshooting The analyzer permanently monitors its functions automatically. Any errors detected by the device are shown on the display. Warning! Troubleshooting work on the components behind the mounting plate may only be carried out by an electrical technician.
  • Page 125 TOCII CA72TOC Troubleshooting Message Cause Tests or remedial action Leakage The leak detector • Check for leaks. has been triggered. • Check the leak alarm for an electrical short-circuit of the spring Leaks in the measuring contacts. device if the springs of •...
  • Page 126 Troubleshooting TOCII CA72TOC Message Cause Tests or remedial action Supply water The pressure sensor • Check the water supply. failure for monitoring the • Check signal processing (I/O card slot No. 35, switch input I3): water supply has Go to the programming module PRG/TEST/INPUTS/SWITCH been triggered.
  • Page 127 TOCII CA72TOC Troubleshooting Message Cause Tests or remedial action Faulty The calibration line • Have the standard solutions been prepared properly? adjustment slope is negative or • Do the two standard solutions have the same concentration? (adjustment zero. • Have the standard solutions been swapped?

  • Page 128: Spare Parts

    Troubleshooting TOCII CA72TOC Spare parts pH electrode for strip champer Order No.: CPS71-1BB2GSA Wear parts kit for one year Order No.: 71095156 for versions with standard furnaces Description Quantity Flange gasket D 53.9 x 63 x 3.1 mm O-ring D 36.09 x 3.53 mm FKM O-ring D 1.5 x 1.5 mm FPM...
  • Page 129 TOCII CA72TOC Troubleshooting Order No.: 71095149 for versions with heated salt trap Includes all parts of 71095149 and additionally: Description Quantity O-ring D 64 x 2.5 mm FPM Sealing glas tube heated filter Filter cartridge 25 x 64 20μ PTFE Maintenance tool kit Order No.: 71102317...

  • Page 130: Return

    Troubleshooting TOCII CA72TOC Wear parts kit for acid filter Order No.: 71101607 Description Quantity Zink granules, 60g pack Copper powder, 50g pack Glass fiber for acid filter, 24 x 230 mm Wear parts kit for predilution pump Order No.: 71101608...

  • Page 131: Decommissioning

    TOCII CA72TOC Troubleshooting Decommissioning Warning! Wear protective gloves, protective goggles and a protective laboratory coat! There is a risk of infection if you into contact with wastewater. Proceed as follows to take the analyzer out of service: Switch off the wastewater pump.

  • Page 132: Input

    2.5 A, slow-blow, design: fine-wire fuse 6.3 x 32 Relay 4 A per relay, slow-blow, design: TR5 Power unit 2 A, slow-blow, design: fine-wire fuse 5 x 20 Note! TOCII CA72TOC is suitable for connection to industrial power supply systems in accordance with EN 61326-1, Class A. Endress+Hauser...

  • Page 133: Technical Data

    TOCII CA72TOC Technical Data 10.4 Performance characteristics In accordance with ISO 15839 The performance characteristics have been determined in accordance with ISO 15839, Annex B. 300 μl sample were metered into the TOCII (CA72TOC-B1A0B1) per measurement. This resulted in a measuring range from 4 to 800 mg/l.

  • Page 134: Index

    TOCII CA72TOC Index Accessories........123 Hose replacement Adjusting pump P2.
  • Page 135 TOCII CA72TOC Opening the circuit ......103 Technical Data ....... . 133 Operating elements .
  • Page 136 TOCII CA72TOC Endress+Hauser...
  • Page 137 Erklärung zur Kontamination und Reinigung Please reference the Return Authorization Number (RA#), obtained from Endress+Hauser, on all paperwork and mark the RA clearly on the outside of the box. If this procedure is not followed, it may result in the refusal of the package at our facility.
  • Page 138 www.endress.com/worldwide BA448C/07/en/06.10 71118197 Printed in Germany / FM+SGML 6.0 / DT 71118197...

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