Endress+Hauser TOC Analyzer CA78 User manual

Products Solutions Services
Operating Instructions
TOC Analyzer CA78
Determination of total organic carbon (TOC) in the trace
range
Powerful compact device
BA02219C/07/EN/01.21-00
71552244
2021-12-15

TOC Analyzer CA78 Table of contents
Endress+Hauser 3
Table of contents
1 About this document ................ 4
1.1 Warnings ............................ 4
1.2 Symbols .............................. 4
1.3 Symbols on the device ................... 4
1.4 Documentation ........................ 4
2 Basic safety instructions ............ 5
2.1 Requirements for the personnel ............ 5
2.2 Intended use .......................... 5
2.3 Workplace safety ....................... 5
2.4 Operational safety ...................... 5
2.5 Product safety ......................... 6
3 Incoming acceptance and product
identification ....................... 7
3.1 Incoming acceptance .................... 7
3.2 Product identification .................... 7
3.3 Scope of delivery ....................... 8
4 Product description ................. 9
4.1 Product design ......................... 9
4.2 Process diagram ...................... 10
4.3 Socket assignment ..................... 10
5 Mounting ......................... 12
5.1 Mounting requirements ................. 12
5.2 Mounting the analyzer .................. 13
5.3 Post-mounting check ................... 14
6 Electrical connection .............. 16
6.1 Connecting instructions ................. 16
6.2 Connecting the analyzer ................. 16
6.3 Ensuring the degree of protection .......... 16
6.4 Post-connection check .................. 16
7 Operation options ................. 17
7.1 Overview of operation options ............ 17
7.2 Structure and function of the operating
menu .............................. 17
7.3 Access to the operating menu via the local
display ............................. 18
8 Commissioning .................... 19
8.1 Function check ....................... 19
8.2 Login procedure ....................... 19
8.3 Configuring the measuring device .......... 19
9 Operation ......................... 33
10 Diagnostics and troubleshooting ... 34
10.1 Replacing the hose system ............... 34
10.2 Firmware history ...................... 35
11 Maintenance ...................... 36
11.1 Maintenance schedule .................. 36
11.2 Maintenance tasks ..................... 36
11.3 Taking out of service ................... 39
12 Repair ............................ 40
12.1 Spare parts .......................... 40
12.2 Return .............................. 40
12.3 Disposal ............................ 40
13 Accessories ....................... 41
14 Technical data .................... 42
14.1 Input ............................... 42
14.2 Output ............................. 42
14.3 Current outputs, active .................. 42
14.4 Power supply ......................... 43
14.5 Performance characteristics .............. 43
14.6 Environment ......................... 43
14.7 Process ............................. 44
14.8 Mechanical construction ................ 44
Index .................................. 45

About this document TOC Analyzer CA78
4 Endress+Hauser
1 About this document
1.1 Warnings
Structure of information Meaning
LDANGER
Causes (/consequences)
If necessary, Consequences of
non-compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation will result in a fatal or serious
injury.
LWARNING
Causes (/consequences)
If necessary, Consequences of
non-compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation can result in a fatal or serious
injury.
LCAUTION
Causes (/consequences)
If necessary, Consequences of
non-compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid this situation can result in minor or more serious injuries.
NOTICE
Cause/situation
If necessary, Consequences of
non-compliance (if applicable)
‣Action/note
This symbol alerts you to situations which may result in damage to
property.
1.2 Symbols
Symbol Meaning
Additional information, tips
Permitted or recommended
Not permitted or not recommended
Reference to device documentation
Reference to page
Reference to graphic
 Result of a step
1.3 Symbols on the device
Reference to device documentation
1.4 Documentation
The following manuals, which complement these Operating Instructions, can be found on
the product pages on the Internet:
Technical Information TOC Analyzer CA78, TI01622C

TOC Analyzer CA78 Basic safety instructions
Endress+Hauser 5
2 Basic safety instructions
2.1 Requirements for the personnel
• Installation, commissioning, operation and maintenance of the measuring system may
be carried out only by specially trained technical personnel.
• The technical personnel must be authorized by the plant operator to carry out the
specified activities.
• The electrical connection may be performed only by an electrical technician.
• The technical personnel must have read and understood these Operating Instructions
and must follow the instructions contained therein.
• Faults at the measuring point may only be rectified by authorized and specially trained
personnel.
Repairs not described in the Operating Instructions provided must be carried out only
directly at the manufacturer's site or by the service organization.
2.2 Intended use
The analyzer is designed to determine the total organic carbon in ultrapure water
applications that meet the following conditions:
• Conductivity < 10 µS/cm
• pH range: neutral
Use of the device for any purpose other than that described, poses a threat to the safety of
people and of the entire measuring system and is therefore not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.
2.3 Workplace safety
As the user, you are responsible for complying with the following safety conditions:
• Installation guidelines
• Local standards and regulations
Electromagnetic compatibility
• The product has been tested for electromagnetic compatibility in accordance with the
applicable international standards for industrial applications.
• The electromagnetic compatibility indicated applies only to a product that has been
connected in accordance with these Operating Instructions.
2.4 Operational safety
Before commissioning the entire measuring point:
1. Verify that all connections are correct.
2. Ensure that electrical cables and hose connections are undamaged.
3. Do not operate damaged products, and protect them against unintentional operation.
4. Label damaged products as defective.
During operation:
‣If faults cannot be rectified:
products must be taken out of service and protected against unintentional operation.

Basic safety instructions TOC Analyzer CA78
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2.5 Product safety
2.5.1 State-of-the-art technology
The product is designed to meet state-of-the-art safety requirements, has been tested, and
left the factory in a condition in which it is safe to operate. The relevant regulations and
international standards have been observed.
2.5.2 IT security
We only provide a warranty if the device is installed and used as described in the
Operating Instructions. The device is equipped with security mechanisms to protect it
against any inadvertent changes to the device settings.
IT security measures in line with operators' security standards and designed to provide
additional protection for the device and device data transfer must be implemented by the
operators themselves.

TOC Analyzer CA78 Incoming acceptance and product identification
Endress+Hauser 7
3 Incoming acceptance and product
identification
3.1 Incoming acceptance
1. Verify that the packaging is undamaged.
 Notify the supplier of any damage to the packaging.
Keep the damaged packaging until the issue has been resolved.
2. Verify that the contents are undamaged.
 Notify the supplier of any damage to the delivery contents.
Keep the damaged goods until the issue has been resolved.
3. Check that the delivery is complete and nothing is missing.
 Compare the shipping documents with your order.
4. Pack the product for storage and transportation in such a way that it is protected
against impact and moisture.
 The original packaging offers the best protection.
Make sure to comply with the permitted ambient conditions.
If you have any questions, please contact your supplier or your local Sales Center.
3.2 Product identification
3.2.1 Nameplate
The nameplate provides you with the following information on your device:
• Manufacturer identification
• Order code (device version)
• Serial number
• Extended order code
• Power supply
• Degree of protection
• (Permitted) ambient conditions
‣Compare the information on the nameplate with the order.
3.2.2 Product identification
Product page
www.endress.com/ca78
Interpreting the order code
The order code and serial number of your product can be found in the following locations:
• On the nameplate
• In the delivery papers
Obtaining information on the product
1. Open www.endress.com.
2. Call up the site search (magnifying glass).
3. Enter a valid serial number.
4. Search.
 The product structure is displayed in a popup window.

Incoming acceptance and product identification TOC Analyzer CA78
8 Endress+Hauser
5. Click on the product image in the popup window.
 A new window (Device Viewer) opens. All of the information relating to your
device is displayed in this window as well as the product documentation.
3.2.3 Manufacturer address
Endress+Hauser Conducta GmbH+Co. KG
Dieselstraße 24
D-70839 Gerlingen
3.3 Scope of delivery
The scope of delivery comprises:
• 1 analyzer with the configuration ordered
• 1 installation kit
• 1 certificate of calibration
• 1 x Operating Instructions
‣If you have any queries:
Please contact your supplier or local sales center.

TOC Analyzer CA78 Product description
Endress+Hauser 9
4 Product description
4.1 Product design
3
6
1
2
4
5
7
8
9
10
11
12
13
A0046933
 1 Product design
1 Main switch
2 USB port
3 Display
4 Analog output 1
5 Analog output 2
6 Housing lock
7 Fluid inlet, sample, UNF ¼ - 28 (order option)
8 Fluid inlet 1, UNF ¼ - 28
9 Fluid inlet 2, UNF ¼ - 28 (order option)
10 Fluid inlet 3, UNF ¼ - 28 (order option)
11 Fluid outlet, waste, UNF ¼ - 28
12 Fan housing with filter mat
13 Cable gland for power supply

Product description TOC Analyzer CA78
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4.2 Process diagram
3
1
2
4
5
6L 2F
U
V
L 1F
V1
V2
V3
A0046935
 2 Process diagram
1 Waste
2 Sample
3 Input 1
4 Input 2
5 Input 3
6 Pump
V1 -
V3
Valve 1, valve 2 (order option) and valve 3 (order option)
LF1 -
LF2
Conductivity and temperature sensors
UV UV lamp (12 VDC)
4.3 Socket assignment
4.3.1 Socket assignment (system with a connection socket)
Socket Pin Description
A0046897
1: 4 (0) - 20 mA (GND)
2: 4 (0) - 20 mA (+)
TOC (0 to set limit)
3: 4 (0) - 20 mA (GND)
4: 4 (0) - 20 mA (GND)
Δ conductivity (0 to set limit)
5: Relay
6: Relay
Group error message or limit value overshoot depending on the
selected option
Pin 1/2: Provides an analog signal between 4 and 20 mA for the TOC measured value
between 0 and the limit (to be configured in the Settings menu, Options 1 tab).
Pin 3/4: Provides an analog signal between 4 and 20 mA for the Δ conductivity value
between 0 and the limit in μS/cm (to be configured in the Settings menu, Service 1 tab).
Pin 5/6: Acts as an NO contact if the configured TOC or conductivity limit value is
exceeded in the "analog output" option, or as an NC contact in the option with a group error
message in the event of a power failure, a reaction of the leak, lamp or pressure sensor
and if one of the two conductivity sensors is over range.
The measured value is updated every minute. During a calibration, the last value is
displayed until a new measurement is started.

TOC Analyzer CA78 Product description
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4.3.2 Socket assignment (system with two connection sockets)
Output 1
Socket Pin Description
A0046897
1: 4 (0) - 20 mA (GND)
2: 4 (0) - 20 mA (+)
TOC 1 (0 to set limit)
3: 4 (0) - 20 mA (GND)
4: 4 (0) - 20 mA (GND)
Δ conductivity (0 to set limit)
5: Relay
6: Relay
Group error message or limit value overshoot depending on the
selected option
Pin 1/2: Provides an analog signal between 4 and 20 mA for the TOC measured value at
the SAMPLE input between 0 and the limit (to be configured in the Settings menu,
Options 1 tab).
Pin 3/4: Provides an analog signal between 4 and 20 mA for the Δ conductivity value
between 0 and the limit in μS/cm (to be configured in the Settings menu, Service 1 tab).
Pin 5/6: Acts as an NO contact if the configured TOC or conductivity limit value is
exceeded in the "analog output" option, or as an NC contact in the option with a group error
message in the event of a power failure, a reaction of the leak, lamp or pressure sensor
and if one of the two conductivity sensors is over range.
4.3.3 Output 2
Socket Pin Description
A0046897
1: 4 (0) - 20 mA (GND)
2: 4 (0) - 20 mA (+)
TOC 2 (0 to set limit)
3: 4 (0) - 20 mA (GND)
4: 4 (0) - 20 mA (GND)
TOC 3 (0 to set limit)
5: Controller (GND)
6: Controller (+)
Controller input / trigger for 24 V DC
Pin 1/2: Provides an analog signal between 4 and 20 mA for the TOC measured value at
INPUT 2 between 0 and the limit (to be configured in the Settings menu, Options 1 tab).
Pin 3/4: Provides an analog signal between 4 and 20 mA for the TOC measured value at
INPUT 3 between 0 and the limit (to be configured in the Settings menu, Options 1 tab).
Pin 5/6: External controller input / trigger, measurement is active when the voltage is
applied and stops if the voltage is 0 V.
The measured value is updated every minute. During a calibration, the last value is
displayed until a new measurement is started.

Mounting TOC Analyzer CA78
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5 Mounting
5.1 Mounting requirements
5.1.1 Dimensions
290 41(11. )
500 (19.68)
200 (7.87)
A0046932
 3 Dimensions in mm (in)
5.1.2 Mounting options
The analyzer is designed for bench-top mounting and wall mounting.
The following graphic shows the location of the blind rivet nuts on the back of the
housing. They can be used to secure a mounting frame. The mounting frame for wall
mounting is not included in the delivery.

TOC Analyzer CA78 Mounting
Endress+Hauser 13
264 (10.39)
450 (17.72)
18 (0.70)
18 (0.70)
25 (0.98)
25 (0.98)
1
A0047197
 4 Rear of the housing
1 Blind rivet nut
5.2 Mounting the analyzer
LWARNING
The device is live!
Risk of electric shock!
‣Do not connect the analyzer to the electricity supply before the installation work is
completed and the media are connected.
‣Follow the instructions in the "Electrical connection" section.
5.2.1 Mounting sequence
Bench-top mounting
1. Place the analyzer on an even, vibration-free surface.
2. Open the front door of the housing and check the interior structure for visible signs
of damage.
3. Check all the built-in fluid connections. The hoses must not be bent or damaged.
4. Check all the fluid couplings to ensure they are fitted securely (tighten by hand).

Mounting TOC Analyzer CA78
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5. After the visual inspections, it is time to mount the sample feed lines and the waste
line of the TOC system. It is important to keep the lines as short as possible and,
when shortening, to cut them straight at a right angle with a hose cutter.
Mounting on a wall
1. Open the front door of the housing and check the interior structure for visible signs
of damage.
2. Check all the built-in fluid connections. The hoses must not be bent or damaged.
3. Check all the fluid couplings to ensure they are fitted securely (tighten by hand).
4. After the visual inspections, it is time to mount the sample feed lines and the waste
line of the TOC system. It is important to keep the lines as short as possible and,
when shortening, to cut them straight at a right angle with a hose cutter.
5. Mount the customer-specific mounting frame on the wall.
6. Mount the housing on the mounting frame.
Electrical connection
1. Connect the signal outputs →  10.
2. Plug the mains plug into the socket (240 V, 50/60 Hz or optionally 100 V, 50/60
Hz).
5.2.2 Connecting the media
1
2
3
4
5
6
78
A0047048
 5 Analyzer, right side panel
1 Analog output 1 4 Input 1 7 Waste
2 Analog output 2 5 Input 2 (order option) 8 Power connection
3 Sample 6 Input 3 (order option)
Analyzer sample outlet
The sample is drained (waste sample) via a hose.
‣Route the hose in such a way that backpressure cannot form.
5.3 Post-mounting check
1. Check whether all the connections are secure and do not have any leaks.

TOC Analyzer CA78 Mounting
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2. Inspect all the hoses for any damage.
 Replace damaged hoses.

Electrical connection TOC Analyzer CA78
16 Endress+Hauser
6 Electrical connection
6.1 Connecting instructions
LWARNING
The device is live!
Risk of electric shock! The line filter, the overvoltage module and the main switch are still
connected to the power supply even when the main switch is switched off!
‣Disconnect the device from the power supply (unplug the mains plug).
‣Before connecting, ensure that the mains voltage matches the voltage indicated on the
nameplate.
‣Ensure that the analyzer is sufficiently grounded via the mains connection.
‣Before establishing the electrical connection, verify that the pre-installed power cable
meets the local national electrical safety specifications.
6.2 Connecting the analyzer
‣Plug the mains plug into the socket (240 V, 50/60 Hz or optionally 100 V, 50/60 Hz).
6.3 Ensuring the degree of protection
Only the mechanical and electrical connections which are described in these instructions
and which are necessary for the required, designated use, may be carried out on the device
delivered.
‣Exercise care when carrying out the work.
Otherwise, the individual types of protection (Ingress Protection (IP), electrical safety, EMC
interference immunity) agreed for this product can no longer be guaranteed due,
for example to covers being left off or cable (ends) that are loose or insufficiently secured.
6.4 Post-connection check
Carry out the following checks once you have made the electrical connection:
Device condition and specifications Notes
Are the cables free from damage on the outside? Visual inspection
Electrical connection Notes
Does the supply voltage of the connected transmitter match the data
on the nameplate?
240 V AC 50/60 Hz
100 V AC 50/60 Hz
Are the current outputs shielded and connected?
Are the connected cables provided with strain relief?
Are the cable types properly isolated from one another? Route the power cable and signal cables
separately from one another over the
entire route. Separate cable ducts are
ideal.
Is the cable run correct, without loops and cross-overs?
Are the power cable and signal cables connected correctly and in
accordance with the wiring diagram?

TOC Analyzer CA78 Operation options
Endress+Hauser 17
7 Operation options
7.1 Overview of operation options
3
1
2
A0047049
 6 Operating elements
1 Main switch
2 USB port
3 Touch screen monitor
7.2 Structure and function of the operating menu
The analyzer has the following menus:
• Measure online
• Viewer (History)
• Qualification (Calibration)
• System (Service)
• Settings (Advanced settings and service)
A0046941

Operation options TOC Analyzer CA78
18 Endress+Hauser
7.3 Access to the operating menu via the local display
Key Function
Measure ‣Press the key.
 TOC measurement is started.
Viewer ‣Press the key.
 The Viewer menu is opened. All TOC measured values can be viewed via this menu.
Qualification ‣Press the key.
 The Qualification menu is opened. Functions can be selected via this menu.
System ‣Press the key.
 The System menu is opened. Function checks on the most important components can
be performed in this menu.
Settings ‣Press the key.
 The Settings menu is opened. Device parameters can be configured in this menu.

TOC Analyzer CA78 Commissioning
Endress+Hauser 19
8 Commissioning
8.1 Function check
Incorrect or improperly connected hose connections cause liquid to leak and can cause
damage!
‣Check all connections and ensure they have been established correctly.
‣In particular, check all hose connections to ensure they are secure and liquid cannot
escape.
Incorrect power supply will damage the device!
‣Ensure that the supply voltage matches the voltage indicated on the nameplate.
8.2 Login procedure
1. Enter the four-digit ID (2199).
2. Press OK in the Login window.
3. Enter the four-digit PIN (9708).
4. Press OK in the Login window.
If you press the Enter key of a connected keyboard, or use the mouse to click on the
next line, these actions are not performed.
8.3 Configuring the measuring device
8.3.1 Performing the measurement
Before initial commissioning, a rinsing process (a measurement) must be performed
for at least 30 minutes. In the event of larger impurities and contamination, rinsing
(measurement) must continue until the same values are consistently displayed.
1. Press the Measure key in the main menu.
 A pop-up window opens.
2. Press the Yes key.
 The program starts by rinsing the system in order to prepare for the TOC
measurement.
3. Set the rinse time:
Open the Settings menu and set the rinse time →  27.
4. Change the time intervals:
Select the time intervals by pressing the appropriate key below the chart.
5. Display the history:
Press the Viewer key in the main menu.
 The Viewer menu is opened and the history is displayed →  22. This does not
interrupt the measurement.
6. Interrupt the measurement:
Exit the Measure menu, e.g. by switching to the Settings menu.
Once the rinsing process is finished, the measurement is started automatically. The TOC,
conductivity and temperature values are shown on the display. The measured values are
shown in the chart on the right-hand side. If the TOC or conductivity value exceeds the
configured limit value, the value is displayed in red. In addition, a warning is output via an
analog output (optional). The limit can be shown as a red line in the chart.

Commissioning TOC Analyzer CA78
20 Endress+Hauser
A0046940
Warnings
If the TOC and/or conductivity is above the configured limit, the value is displayed in red
digits. In addition, a warning is output via a digital output (optional). The limit can be
shown as a red line in the chart.
A0046943
 7 Measurement over range limit
Leak in the system
If there is a leak in the system, the analyzer stops the measurement automatically and
closes valve 1. Once the leak has been found and eliminated, the analyzer starts measuring
again (only if the Continue after error option is enabled in the Settings menu, Options 2
tab →  27. The leak sensor in the system must be dried thoroughly beforehand. The
leak sensor is located on the base of the device on the right-hand side.