Endress+Hauser analytikjena TOC module User manual

Operating Manual
TOC module

Analytik Jena AG
Konrad-Zuse-Str.1
07745 Jena Germany
Phone + 49 3641 / 77 70
Fax + 49 3641 / 77 92 79
Email [e-mail]
Analytik Jena AG
Konrad-Zuse-Str. 1
07745 Jena Germany
Phone + 49 3641 / 77-7407 (Hotline)
Email [e-mail]
http://www.analytik-jena.com
Microsoft and Windows are registered trademarks of Microsoft Corp.
The identification with ® or TM is omitted in this manual.
11-889.684
January 2010
Analytik Jena AG
© Copyright 2010, Analytik Jena AG
Manufacturer
Service
General information
Copyrights and
Trademarks
Documentation number
Edition
Implementation of the
Technical Documentation

Table of Contents
TOC module Edition 01/2010 i
Table of Contents
1Basic information................................................................... 1
1.1 User manual notes.................................................................................1
1.2 Application.............................................................................................2
1.3 Proper use.............................................................................................2
1.4 Warranty and liability..............................................................................2
1.5 Scope of delivery ...................................................................................3
2Technical data........................................................................ 4
3Safety instructions................................................................. 5
3.1 General notes........................................................................................5
3.2 Safety instructions for the TOC module..................................................5
3.2.1 Summary of safety instructions..............................................................5
3.2.2 Safety instructions - operation................................................................6
3.2.3 Safety instructions - protection against explosion and fire......................6
3.2.4 Safety instructions - electrical equipment...............................................6
3.2.5 Handling of auxiliary and operating materials.........................................7
3.2.6 Behavior during emergencies.................................................................8
4Technical description ............................................................ 9
4.1 System design .......................................................................................9
4.1.1 Overview................................................................................................9
4.1.2 Combustion tube..................................................................................10
4.1.3 Sample preparation..............................................................................11
4.1.3.1 Sample preparation in the TOC combustion tube.................................12
4.1.3.2 Sample preparation in the TIC reactor .................................................12
4.1.4 Components for measuring gas drying and cleaning............................12
4.1.4.1 Condensation coil in the basic module.................................................12
4.1.4.2 TIC condensation unit in the TOC module............................................12
4.1.4.3 Water traps..........................................................................................13
4.1.4.4 Halogen trap........................................................................................13
4.1.5 Pneumatic/hose system.......................................................................13
4.1.5.1 Hose diagram ......................................................................................13
4.1.5.2 Connection method..............................................................................14
4.1.5.3 Condensate pump................................................................................15

Table of Contents
ii Edition 01/2010 TOC module
4.1.6 Detector...............................................................................................15
4.1.7 Indicator and control elements, connectors..........................................15
4.1.7.1 LED displays........................................................................................15
4.1.7.2 Equipment switch, interfaces................................................................15
4.1.7.3 Gas connectors....................................................................................18
4.1.7.4 Connector for waste.............................................................................18
4.2 Function...............................................................................................19
4.3 Measuring method...............................................................................19
4.3.1 TC analysis..........................................................................................19
4.3.2 TOC analysis .......................................................................................20
4.3.3 TIC analysis.........................................................................................20
4.3.4 NPOC analysis.....................................................................................20
4.4 Catalysts..............................................................................................20
5Transport and storage......................................................... 21
5.1 Transport .............................................................................................21
5.1.1 Preparation of the TOC module for transport .......................................21
5.1.2 Transport notes....................................................................................21
5.1.3 Moving the TOC module in the laboratory............................................22
5.2 Storage................................................................................................22
5.3 Recommissioning after transport or storage.........................................23
5.3.1 Assembling the components................................................................23
5.3.2 Connecting the TOC module................................................................24
6First commissioning............................................................ 25
6.1 Site requirements.................................................................................25
6.1.1 Installation conditions...........................................................................25
6.1.2 Space ..................................................................................................25
6.1.3 Energy supply......................................................................................26
6.1.4 Gas supply...........................................................................................26
6.1.5 Unpacking and positioning the TOC module........................................26
7Operation.............................................................................. 27
7.1 Basic information .................................................................................27
7.2 General information for the analysis work ............................................27
7.2.1 Standard commissioning......................................................................28
7.3 Performing measurements...................................................................29
8Fault removal........................................................................ 30

Table of Contents
TOC module Edition 01/2010 iii
8.1 General information .............................................................................30
8.2 Equipment faults and analytical problems............................................30
9Maintenance and care.......................................................... 33
9.1 Service intervals...................................................................................33
9.2 Replacing the water traps ....................................................................34
9.3 Replacing the halogen trap ..................................................................35
9.4 Exchanging the catalyst.......................................................................36
9.4.1 Lifetime of the catalyst .........................................................................36
9.4.2 Removing the combustion tube............................................................36
9.4.3 Filling the combustion tube ..................................................................37
9.4.4 Inserting the combustion tube..............................................................38
9.5 Regenerating the TIC reactor...............................................................39
9.6 Cleaning the TC condensation vessel..................................................40
9.7 Removing and installing the condensation coil.....................................41
9.7.1 Removing and cleaning the condensation coil .....................................41
9.7.2 Inserting the condensation coil.............................................................41
9.8 Removing and replacing the pump hose..............................................42
9.9 Replacing hose connections ................................................................42
9.10 Checking the system for tightness........................................................43
9.11 Exchanging the septums......................................................................44
9.12 Spare part list.......................................................................................45
9.13 Notes on ordering ................................................................................46
10 Waste disposal..................................................................... 47
10.1 Waste water.........................................................................................47
10.2 Halogen trap........................................................................................47
10.3 Catalyst................................................................................................47
10.4 TOC module ........................................................................................47

Index of Figures
iv Edition 01/2010 TOC module
Index of Figures
Fig. 1 Front view, TOC module –Door open....................................................9
Fig. 2 View of the basic module, left door open..............................................10
Fig. 3 TOC combustion tube..........................................................................11
Fig. 4 Tube holder for TOC combustion tube .................................................11
Fig. 5 Condensation coil with spherical joint and FAST connector .................12
Fig. 6 Hose diagram TOC module..................................................................14
Fig. 7 Equipment backplate............................................................................17
Fig. 8 TOC combustion tube, filled.................................................................38

Basic information
TOC MODULE Edition 01/2010 1
1Basic information
1.1 User manual notes
The TOC module is a system module of the modular analyzers multi EA®5000 or
multi X®2500. It can only be used in combination with one of the two basic modules.
The control of the modules and the analysis of the measurements is performed with the
software multiWin®.
This user manual is therefore only valid in conjunction with the following documents:
-User manual multi EA®5000 or user manual multi X®2500
-Software manual of the control and analysis software multiWin®
IMPORTANT
Carefully read the above-mentioned documents before connecting the TOC module
to the basic module and using it. Observe in particular the notes in the chapter
"Safety notes" of the user manuals.
The following user manual informs about the design and function of the TOC module
and provides the necessary know-how for the safe handling of the device and its
components to personnel familiar with analysis. The user manual further includes notes
on the maintenance and service of the device and potential causes and remedies of
any faults.
Conventions
Instructions for action which occur in chronological order are numbered and
combined into action units and furnished with the corresponding results.
Lists which are not in chronological order are shown as itemized lists, sub-listings as
bullet points.
Safety notes are indicated by pictographs and signal words. The type and source of
the danger are stated together with notes on preventing the danger. The meaning of
the pictographs and signal words used is explained in the chapter "Safety notes" of the
user manual multi EA®5000 or multi X®2500 (basic module).
The elements of the control and analysis software are indicated as follows:
Buttons and menus are shown in bold and by square brackets (e.g. button
[OK], menu [Method])
Menu and selection sequences are divided by arrows (e.g. menu [Method]
[Edit method])
Window names are shown in italics (e.g. Configuration window)
Field, frame and tab names are shown in bold (e.g. Devices tab,Automatic
initialization frame)

Basic information
2 Edition 01/2010 TOC MODULE
1.2 Application
The expansion of the multi EA®5000 or the multi X®2500 with the TOC module
enables the determination of the carbon content in aqueous samples by digestion with
the aid of thermocatalytic high-temperature oxidation in the presence of special
catalysts according to national and international standards.
1.3 Proper use
The device must only be used for the methods described in this user manual to
determine the carbon content in aqueous samples. Any other use is not as intended!
Only the operator is liable for any damages that result from this.
The operational safety of the TOC module is only ensured during proper use according
to the information in this user manual. The intended use also requires that you observe
the notes in the user manual of the multi EA®5000 or multi X®2500.
1.4 Warranty and liability
The warranty duration and liability comply with the legal requirements and the
provisions in the general terms and conditions of Analytik Jena AG.
Deviations from the intended use described in this user manual result in limitations of
warranty and liability during a damage event. Damage to wearing parts is not included
in the warranty.
Warranty and liability claims are excluded for personal injury and property damage due
to one or several of the following causes:
use of the TOC module other than intended
improper commissioning, operation and service of the TOC module
modifications of the device without prior consultation with Analytik Jena AG
unauthorized intervention in the device
operation of the device with faulty safety equipment or improperly fitted safety
and protection equipment
inadequate monitoring of the device components subject to wear
use of other than original spare parts, wearing parts or consumables
improper repairs
faults due to the non-observance of this user manual

Basic information
TOC MODULE Edition 01/2010 3
1.5 Scope of delivery
IMPORTANT
The scope of delivery is listed in the table below for information purposes.
Completeness is not guaranteed. Modifications are reserved.
When checking the delivered components always refer to the current packing list
included in the scope of delivery.
Name
TOC module, pre-assembled
Mains cable
Connection cable basic device -TOC module, 9 pin
Connection cable basic device –TOC module, 25 pin
TOC combustion tube
Gas connection hose (6x4 mm), 3m
Syringe, 500 µl, calibrated
Replaceable canulas (OD 0.63 mm), set of 3
Syringe 5 ml for phosphoric acid with canula
NPOC hose
Condensation vessel with manual TIC port
Condensation unit with:
Condensation coil
Connection hose to
condensation vessel
FAST connector, straight
TC prefilter
Disposable retention filter
Halogenide trap, filled
Waste canister
Outlet tube, 1m
Consumables:
Pt catalyst
Quartz glass fragments
Quartz glass wool
HT mat
Septums Ø 12.5 mm –manual TIC port
Septum Ø 17 mm –injection port combustion tube
Filling rod for combustion tube
User manual
Packing list

Technical data
4 Edition 01/2010 TOC MODULE
2Technical data
General characteristics
Designation/type
TOC module
Basic device dimensions (W x H x D)
approx. (300 x 470 x 530) mm
Weight
approx. 10 kg
Procedural data
Digestion principle
Thermocatalytic oxidation
Digestion temperature
700 °C (Pt/Al2O3)
up to 900 °C, depending on the catalyst
Detection
NDIR (Non-dispersive infra red absorption)
0 –20 % CO2 in analyte gas
Measuring method
TC, TIC, TOC, NPOC
Sample Feed
Direct injection via injection port with
septum into the combustion tube in the
basic module
Direct injection into the TIC condensation
vessel –TIC manual
Sample volume
(50 –500) µl
Gas supply from the basic device
Oxygen (minimum 4.5)
Preliminary pressure 4 –6 bar
Gas consumption
200 mlmin
Dosing rate
According to the method settings or manual
Measuring gas drying
Condensation and freeze desalination
Electrical variables
Power supply
(110 –240) V AC, 50/60 Hz
Protection
T 4.0 A H (2x)
Typical average power consumption
50 VA
Interface to the basic module
RS 232
Interference suppression
(electromagnetic compatibility)
In accordance with the EC directive
2004/108/EC
Environmental conditions
Temperature during storage
(15 –55) °C
Temperature during operation
(20 –35) °C
Humidity during operation
Max. 90 % at +30 °C
Humidity during storage
(10 –30) % (use desiccant)
Air pressure
(0.7 –1.06) bar