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wtw PROTOC 200 Operating Manual

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Operating Manual
PROTOC 200
TOC Analyzer
ba43200e01
11/00

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Summary of Contents for wtw PROTOC 200

  • Page 1 Operating Manual PROTOC 200 TOC Analyzer ba43200e01 11/00...
  • Page 2 © Copyright Weilheim 2000, WTW GmbH & Co. KG Reproduction – including excerpts – only upon express written consent of WTW GmbH & Co. KG, Weilheim. Printed in Germany.

  • Page 3: Table Of Contents

    PROTOC 200 Contents Overview ......... 5 Safety .
  • Page 4 Contents PROTOC 200 Alarm setup menu ......41 5.3.1 Overview ......41 5.3.2...

  • Page 5: Overview

    PROTOC 200 Overview Overview View of equipment Figure 1-1 PROTOC 200 Analyzer Figure 1-2 PROTOC 200 Controller 1 - 5...
  • Page 6 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.

  • Page 7: Safety

    PROTOC 200 Safety 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...

  • Page 8: General Safety Instructions

    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.

  • Page 9: Hazards

    PROTOC 200 Safety Operator obligations The operator of the analyzer must ensure that the following laws and guidelines are adhered to when handling hazardous substances: EG guidelines for industrial safety National laws regarding industrial safety Accident prevention regulations Safety data sheets of the chemicals and consumable substances used.
  • Page 10 Safety PROTOC 200 2 - 10...

  • Page 11: Installation

    PROTOC 200 Installation 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.

  • Page 12: Standard Solution

    Installation PROTOC 200 The table lists the quantities of chemicals that are required: Concentra- Sodium Water for Acid tion persulfate dilution 2.5 % 500 g 20 liters 100 ml 1 kg 20 liters 100 ml 10 % 2 kg 20 liters...

  • Page 13: Cleaning Solution

    PROTOC 200 Installation Weigh out 2.125 g reagent grade, anhydrous potassium hydro- gen phthalate (C8H5O4K) and transfer it to a 1l graduated flask. Add distilled or deionized water. Add 1 ml reagent grade, concentrated phosphoric acid. Top up to the 1l mark with water.

  • Page 14: Prerequisites For Installation

    Installation PROTOC 200 Prerequisites for installation Location The equipment is not designed for outdoor use. 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.

  • Page 15: Installation

    Do not shorten the tubes included; their full length is required for fas- tening the swage locks. Dimensions and space requirements Figure 3-1 PROTOC 200 dimensions (given in mm) Mounting the analyzer Attach the analyzer securely to the mounting wall using the 4 and controller wall fixtures.
  • Page 16 Installation PROTOC 200 Typical wall assembly min. 200 Controller 101.5 Analyzer Figure 3-2 Typical wall assembly with drilled holes (dimensions in mm) Connect the analyzer power cable to Connection A (see Figure 3-3). Connect the controller to Connection B (see Figure 3-3) on the analyzer.
  • Page 17 PROTOC 200 Installation Connections Figure 3-3 Connections Connection Function Power supply Signal output to controller Carrier gas inlet System outlet Sample inlet Standard inlet Reagent inlet Outlet opening Ventilation Dryer and U-tube ventilation Cleaning liquid inlet Cleaning liquid outlet Warning The solution flowing from the drain contains acid and oxidizing sub- stances.

  • Page 18: Sample Conditioning

    Each individual installation may require its own unique sample processing system. 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.

  • Page 19: Electrical Installation

    PROTOC 200 Installation 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...
  • Page 20 Installation PROTOC 200 Ensure that the lamp switch (2) is set to OFF. Figure 3-5 Lamp switch Ensure that the pump switch (3) is set to OFF. Figure 3-6 Pump switch and main switch Plug in the analyzer power cable.

  • Page 21: Connecting The Carrier Gas

    PROTOC 200 Installation 3.4.4 Connecting the carrier gas Carrier gas is used to remove carbon dioxide from the liquid. Gas flow is regulated by fixed and adjustable flow controllers at strategic loca- tions in the analyzer. In the majority of applications, the carrier gas is compressed air.

  • Page 22: Connecting The Outlet

    Installation PROTOC 200 3.4.5 Connecting the outlet Analyzer waste fluid contains excess reaction liquid, sample and gas. The outlet opening must be connected to an open, pressure-free drain. Because the waste fluid contains acidic sodium persulfate, ap- propriate safety precautions must be taken. Brass and copper materi- als may not be used.

  • Page 23: Connecting The Standard Solution

    PROTOC 200 Installation 3.4.7 Connecting the standard solution Prepare the standard solution for calibration in a suitable container as described in section 3.2 P . The container should REPARING SOLUTIONS be large enough for the analyzer to run unattended for some time. The reagent must be replenished at regular intervals.

  • Page 24: Initial Commissioning

    Installation PROTOC 200 3.5 Initial commissioning Note A warm-up period of 1 hour is recommended for the infrared lamp prior to starting up the equipment for the first time. Attention The reaction vessel light source emits ultraviolet light during operation.
  • Page 25 PROTOC 200 Installation Remove one of the plugs from the U-tube. Half fill the U-tube with distilled water using a syringe. Supply the analyzer with gas at a pressure of 2.2 bar (30 psi). Gas flow within the analyzer is preset by the manufacturer and does not normally require adjustment.
  • Page 26 Installation PROTOC 200 Figure 3-9 Carrier gas valve 3 - 26...

  • Page 27: Checklist For Commissioning The Equipment

    Switching on the Carry out the preparatory steps as described in the checklist. equipment Switch on the main power supply to the PROTOC 200 (if it was turned off). Plug in the controller power cable. Switch on the IR detector (if it was turned off).
  • Page 28 Installation PROTOC 200 3 - 28...

  • Page 29: Operation

    PROTOC 200 Operation Operation 4.1 Operation basics This section provides you with basic information regarding analyzer op- eration. The analyzer is operated from the controller: Controller operating elements Figure 4-1 Controller Key functions Function when pressed F keys Select menu items...

  • Page 30: Calibration

    PROTOC 200 4.2 Calibration The PROTOC 200 is calibrated using two points of its measuring range: at 0 % and at a value between 50 % and 100 % of the measuring range. The controller automatically runs through a sequence of zeroing and calibration operations at preset times over a 24-hour period.
  • Page 31 PROTOC 200 Operation Zeroing Using a screwdriver, adjust the ZERO potentiometer (1) on the IR detector in the analyzer until the display reads zero ppm or approx. 1000 Hz. Figure 4-2 IR detector Confirm the new zero point with the UP key.

  • Page 32: Shutting Down The System

    PROTOC 200 4.3 Shutting down the system Because the PROTOC 200 is designed for continuous operation, it need not be shut down at night or over the weekend. Please proceed as follows if it should become necessary to shut the system down: Short-term shutdown Disconnect the controller from the power supply.

  • Page 33: Setup

    PROTOC 200 Setup Setup 5.1 Controller function Overview of the The controller receives a signal from the analyzer and displays it as operation a measurement. Automatic functions such as zeroing, calibration and cleaning are time-controlled. Two alarm points are available that can be adjusted by the user and one sensor alarm is available that indicates analyzer malfunctions.

  • Page 34: Sensor Setup Menu

    Setup PROTOC 200 Sensor setup menu 5.2.1 Overview MAIN MENU (Hauptmenü) SENSOR SETUP (Sensoreinstellungen) SCALE NORMAL CAL EXTENDED SETUP (Einheit) (Nullpunkt/Kalibrierung) (erweitertes Setup) ZERO CAL. CONFIGURE AUTO MODE RANGE SELECT (Nullabgleich) (Kalibrierung) (Intervalle/Zeiten) (Meßbereichswahl) CLEAN ZERO CAL. PURGE (Reinigung) (Nullabgleich) (Kalibrieren) (Spülen)

  • Page 35: Changing The Calibration Point

    PROTOC 200 Setup 5.2.3 Changing the calibration point Calibration / NORMAL Press the ENTER/MENU key. The MAIN MENU appears on the display. Press F1. The SENSOR SETUP menu appears. F1: ZERO This manually activates zeroing and calibration (additional in- formation in section 4.2 C...

  • Page 36: Setting The Measuring Range

    Setup PROTOC 200 5.2.4 Setting the measuring range The analyzer measuring range can be adjusted in the RANGE SELECT menu. This should only be carried out if the analyzer section has also been modified to run at the new range.

  • Page 37: Cleaning

    PROTOC 200 Setup 5.2.5 Cleaning CLEANING The equipment automatically carries out a cleaning cycle 0 to 4 times a day. The duration is set to 3 minutes. Cleaning can also be started manually. The last signal is frozen on the analog output during all clean- ing cycles.

  • Page 38: Zeroing

    Setup PROTOC 200 5.2.6 Zeroing The equipment automatically zeroes 0 to 4 times a day. The duration Zeroing / ZERO can be selected within the range of 5 to 20 minutes, depending on the analyzer response time and application demands. Zeroing can also be started manually.

  • Page 39: Calibration

    PROTOC 200 Setup 5.2.7 Calibration The equipment automatically calibrates 0 to 2 times a day. The calibra- Calibration / tion duration can be selected within the range of 5 to 20 minutes, de- CALIBRATE pending on the analyzer response time and application demands.

  • Page 40: Purging

    Setup PROTOC 200 5.2.8 Purging After each calibration, cleaning and zeroing operation, the equipment PURGE automatically purges the system before updating the display and out- puts. The purging duration can be selected within the range of 5 to 15 minutes. The last signal is frozen on the analog output during all purg- ing cycles.

  • Page 41: Alarm Setup Menu

    PROTOC 200 Setup Alarm setup menu 5.3.1 Overview Two alarm functions are available that can each be switched on or off and that can be set to a value between zero and the measuring range limiting value. MAIN MENU (Hauptmenü)

  • Page 42: Setting The Nominal Alarm Values

    Setup PROTOC 200 5.3.2 Setting the nominal alarm values The sensor alarm indicates a communication fault between the sensor and the analyzer. This alarm is also activated if the values during the last 30 seconds of zeroing or calibration lie outside of the specified dead band (hysteresis).

  • Page 43: Setting Up The Access Code

    PROTOC 200 Setup 5.3.3 Setting up the access code PROTOC 200 settings can be protected by a code function that uses a 3-digit access code. The equipment is delivered with the code function deactivated. Attention Please write down the code if you activate the code function or change the code.

  • Page 44: Display Settings

    Setup PROTOC 200 5.4 Display settings The following display settings can be adjusted: Display brightness Upper and lower display scale limits (range: 0 ... 20 000) Time base for graphic measurement display (8 or 24 hours) Signal averaging (off, 15, 30, 60 seconds) MAIN MENU (Hauptmenü)

  • Page 45: Controller Setup

    PROTOC 200 Setup Press F3. The time base for the graphic display is highlighted (TIME BASE). Set as required with the UP/DOWN keys (8HR or 24HR). Press F4. The setting for the signal averaging is highlighted (SIGNAL AVERAGING OFF, 15, 30 or 60 SEC).

  • Page 46: Setting The Date/Time

    Setup PROTOC 200 Proceed as follows to change the controller settings: 5.5.2 Setting the date/time Press the ENTER/MENU key. The MAIN MENU appears on the display. Press F4. The CONTROLLER SETUP menu appears. The hour setting under TIME/DATE is highlighted.

  • Page 47: Setting The Output Voltage/Current Range

    PROTOC 200 Setup 5.5.4 Setting the output voltage/current range Proceed as follows to finely adjust the range limits of the current or volt- age output to adapt the output to different loads. Press the ENTER/MENU key. The MAIN MENU appears on the display.

  • Page 48: Serial Interface (Option)

    Setup PROTOC 200 5.5.5 Serial interface (option) For controllers equipped with a serial interface, the following settings can be made in the COMMUNICATIONS menu: Baudrate Printer on or off Address Data report every 4 or 24 hours Configuring the Press the ENTER/MENU key. The MAIN MENU appears on interface the display.

  • Page 49: Maintenance

    PROTOC 200 Maintenance Maintenance This section describes service procedures that are to be carried out at regular intervals. 6.1 Weekly maintenance The following weekly maintenance steps take about 30 minutes to com- plete. Check that the quantity of reagent solution is adequate. Re- plenish the reagent solution if necessary.
  • Page 50 Maintenance PROTOC 200 Figure 6-1 Replacing the pump tubes Removing the pump Switch off the power supply. head and tubes Detach the PTFE tubes (1) from the pump tubes (4). Make sure that the marker sleeves (2) are secure. If necessary, plug the ends of the PTFE tubes to prevent fluid from flowing into the analyzer.

  • Page 51: Replacing Individual Pump Tubes

    PROTOC 200 Maintenance Connect the pump tubes to the PTFE tubes, using the flow chart and tube labels as a guide. Switch on the pump. Check that the solutions are being pumped correctly. Check the connections for leakage. 6.3 Replacing individual pump tubes...

  • Page 52: What To Do If

    What to do if... PROTOC 200 What to do if... 7.1 The display responds slowly or not at all to the calibra- tion solution or sample Cause Actions Reagent solution – The reagent solution is too old – Prepare and use a fresh...

  • Page 53: Unstable Readings

    PROTOC 200 What to do if... Cause Actions – Leakage in gas supply – See section 7.1 T HE DISPLAY RESPONDS SLOWLY OR NOT AT ALL TO THE CALIBRATION SOLUTION OR SAMPLE Note Manually carry out zeroing and calibration after troubleshooting. Press the ALARM key to shut off the sensor alarm.
  • Page 54 What to do if... PROTOC 200 7 - 54...

  • Page 55: Technical Data

    PROTOC 200 Technical data Technical data 8.1 Dimensions and weights View of equipment Figure 8-1 View of equipment and dimensions (in mm) Mechanical data Weight Analyzer: approx. 32 kg Controller: approx. 3 kg Assembly type Wall assembly Material Housing: GRP...

  • Page 56: Connections

    Technical data PROTOC 200 8.2 Connections Electrical connection ± Power supply 230 VAC 10 % (50 Hz) data ± 115 VAC 10 % (50 - 60 Hz) Power consumption 230 W Carrier gas connection 1/8 " stainless steel (swage lock)

  • Page 57: Outputs

    PROTOC 200 Technical data 8.3 Outputs Signal output Quantity/type 1 analog output, selectable as 4–20 mA or 1–10 VDC Connections are made to terminal contacts in- side the controller Relays Quantity/type 2 relays, configurable Max. switching voltage 50 VAC Max. switching current...

  • Page 58: Miscellaneous

    Technical data PROTOC 200 8.4 Miscellaneous Operating conditions Operating temperature 5 ... 50 °C Acceptable relative humidity 90 % Certification Equipment protection IP 65 for the analyzer housing class Measuring range 0 ... 20.000 ppm or ppb Accuracy < + 2 % of the measuring range limiting value...

  • Page 59: Appendix

    PROTOC 200 Appendix Appendix 9.1 Flow diagram 9 - 59...

  • Page 60: Socket Connections For The Analog Output

    Appendix PROTOC 200 9.2 Socket connections for the analog output 9 - 60...

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