Endress+Hauser TOCII CA72TOC User manual

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

Endress+Hauser

TOCII CA72TOC
Endress+Hauser 3
Table of contents
1 Safety instructions . . . . . . . . . . . . . . . . 5
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Installation, commissioning and operation . . . . . . . . 5
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Notes on safety icons and symbols . . . . . . . . . . . . . . 6
2 Identification . . . . . . . . . . . . . . . . . . . . 7
2.1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Product structure . . . . . . . . . . . . . . . . . . . . 7
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 8
3 Installation . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Incoming acceptance, transport, storage . . . . . . . . . . 9
3.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . 10
3.2.1 Methods of installation . . . . . . . . . . . . . . . 10
3.2.2 Compressed air and water supply . . . . . . . . 11
3.2.3 Environment . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . 12
3.3.1 Mounting sequence . . . . . . . . . . . . . . . . . . 12
3.3.2 Wall mounting with a pivoting frame . . . . . 12
3.3.3 Mounting on a base frame . . . . . . . . . . . . . 13
3.3.4 Connecting the media . . . . . . . . . . . . . . . . 13
3.3.5 Preparing the chemicals . . . . . . . . . . . . . . . 15
3.4 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 19
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.1 Preparing to wire . . . . . . . . . . . . . . . . . . . . 20
4.1.2 Power distribution . . . . . . . . . . . . . . . . . . . 21
4.1.3 Signal connection . . . . . . . . . . . . . . . . . . . 23
4.1.4 Power unit . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1.5 Distributor connection . . . . . . . . . . . . . . . 25
4.1.6 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 26
5 Operation . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Display and keypad . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Operation during measuring mode . . . . . . . . . . . . . 30
5.3.1 Recording mode . . . . . . . . . . . . . . . . . . . . 30
5.3.2 Spot view . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Standby mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Commissioning . . . . . . . . . . . . . . . . . . 32
6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2.1 Commissioning sequence . . . . . . . . . . . . . . 32
6.2.2 CLR start . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3 Programming mode . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3.1 Menu SETTING - RANGE DATA . . . . . . . . 35
6.3.2 Menu SETTING - SET CLOCK . . . . . . . . . 36
6.3.3 Menu SETTING - ALARM LIMITS . . . . . . . 36
6.3.4 Menu SETTING - BASIC DATA . . . . . . . . . 37
6.3.5 Menu SETTING - SET DEFAULTS . . . . . . . 38
6.3.6 Menu SETTING - MEASURING SITE . . . . 38
6.3.7 Menu LISTS - MIN MAX AVERAGE . . . . . 38
6.3.8 Menu LISTS - MAINTENANCE RECORD . 39
6.3.9 Menu LISTS - ALARM RECORD . . . . . . . . 40
6.3.10 Menu LISTS - SHOW COMPLETE
RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.11 Menu TEST - TEST OF INPUTS . . . . . . . . . 42
6.3.12 Menu TEST - TEST OF OUTPUTS . . . . . . . 44
6.3.13 Menu TEST - TEST FREQUENCY I/O . . . . 45
6.3.14 Menu TEST - TEST COM2 . . . . . . . . . . . . 45
6.3.15 Menu TEST - MEASUREMENT OFF . . . . . 46
6.3.16 Two-channel: external changeover . . . . . . 46
6.3.17 Two-channel: time-controlled changeover . 48
6.4 Optimizing the analyzer . . . . . . . . . . . . . . . . . . . . . 50
6.4.1 Adjusting the measuring range . . . . . . . . . . 50
6.4.2 Influence on dosing pump P2 on the
measuring signal . . . . . . . . . . . . . . . . . . . . 50
6.4.3 Operating the analyzer with high salt
loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4.4 Adjusting the gas flow . . . . . . . . . . . . . . . . 51
6.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

TOCII CA72TOC
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7 Maintenance . . . . . . . . . . . . . . . . . . . . 55
7.1 Cleaning the housing . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.3 Topping up reagents . . . . . . . . . . . . . . . . . . . . . . . 60
7.4 Topping up or replacing the standard . . . . . . . . . . . 61
7.5 Entering the concentration of the standard solution 62
7.6 Service software . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.7 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.7.1 Replacing the hoses on pumps P1 and P4 . . 63
7.7.2 Replacing the hose on pump P2 . . . . . . . . . 72
7.7.3 Replacing the hose on pump P3 . . . . . . . . . 75
7.7.4 Adjusting pump P2 . . . . . . . . . . . . . . . . . . 79
7.7.5 Cleaning dilution water pump P5 . . . . . . . . 82
7.8 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.8.1 Adjusting the analyzer . . . . . . . . . . . . . . . . 84
7.8.2 Calibrating the analyzer . . . . . . . . . . . . . . . 86
7.8.3 Empty volume dosing . . . . . . . . . . . . . . . . 88
7.8.4 Adjusting the pH sensor . . . . . . . . . . . . . . . 91
7.9 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.9.1 Screen flushing . . . . . . . . . . . . . . . . . . . . . 95
7.9.2 Power flush . . . . . . . . . . . . . . . . . . . . . . . . 96
7.9.3 Bypass screen . . . . . . . . . . . . . . . . . . . . . . 97
7.9.4 Strip and separation chamber . . . . . . . . . . . 99
7.9.5 Opening the circuit . . . . . . . . . . . . . . . . . 103
7.9.6 Combustion pipe . . . . . . . . . . . . . . . . . . . 105
7.9.7 Leakage test . . . . . . . . . . . . . . . . . . . . . . 111
7.10 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.10.1 Replacing the acid filter . . . . . . . . . . . . . . 113
7.10.2 Replacing the gas filter . . . . . . . . . . . . . . . 115
7.10.3 Replacing the O2 filter . . . . . . . . . . . . . . . 117
7.10.4 Replacing the heated salt trap . . . . . . . . . . 119
8 Accessories . . . . . . . . . . . . . . . . . . . . 123
9 Troubleshooting . . . . . . . . . . . . . . . . 124
9.1 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.4 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . 132
9.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
10 Technical Data. . . . . . . . . . . . . . . . . . 133
10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.2 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.4 Performance characteristics . . . . . . . . . . . . . . . . . 134
10.5 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10.6 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10.7 Mechanical construction . . . . . . . . . . . . . . . . . . . 134
Index . . . . . . . . . . . . . . . . . . . . . . . . . 136

TOCII CA72TOC Safety instructions
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1 Safety instructions
1.1 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)
• Control of process wastewater
• Monitoring of industrial surface waters
• Municipal wastewater monitoring
• Recording the carbon load for nutrient dosing
Any other use than the one described here compromises the safety of persons and the entire
measuring system and is not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.
1.2 Installation, commissioning and operation
Please note the following items:
• Installation, commissioning, operation and maintenance of the measuring system must only be
carried out by trained technical personnel.
Trained personnel must be authorized for the specified activities by the system operator.
• Electrical connection must only be carried out by a certified electrician.
• Technical personnel must have read and understood these Operating Instructions and must
adhere to them.
• Before commissioning the entire measuring point, check all the connections. Ensure that
electrical cables and hose connections are not damaged.
• Do not operate damaged products and secure them against unintentional commissioning.
Mark the damaged product as being defective.
• Measuring point faults may only be rectified by authorized and specially trained personnel.
• If faults can not be rectified, the products must be taken out of service and secured against
unintentional commissioning.
• Repairs not described in these Operating Instructions may only be carried out at the
manufacturer’s or by the service organization.
1.3 Operational safety
The analyzer has been designed and tested to the highest standards and left the factory in perfect
functioning order.
Relevant regulations and European standards have been met.
As the user, you are responsible for complying with the following safety conditions:
• Installation instructions
• Local prevailing standards and regulations.
Electromagnetic compatibility
With regard to electromagnetic compatibility, this device has been tested in accordance with the
applicable European standards for industrial applications.
The electromagnetic compatibility indicated only applies to a device that has been connected in
accordance with the instructions in these Operating Instructions.

Safety instructions TOCII CA72TOC
6Endress+Hauser
1.4 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.
Please enclose the completed "Declaration of contamination" (copy the second last page of these
Operating Instructions) with the packaging and the transportation documents.
No repair without completed "Declaration of contamination"!
1.5 Notes on safety icons and symbols
Electrical symbols
#Warning!
This symbol alerts you to hazards that can cause serious damage to the instrument or to persons if
ignored.
"Caution!
This symbol alerts you to possible faults which could arise from incorrect operation. They could
cause damage to the instrument if ignored.
!Note!
This symbol indicates important items of information.
%Direct Current (DC)
A terminal at which DC is applied or through which DC flows.
&Alternating Current (AC)
A terminal at which (sine-form) AC is applied or through which AC flows.
)Ground connecting
A terminal which, from the user’s point of view, is already grounded using a grounding system.
*Protective ground terminal
A terminal which must be grounded before other connections may be set up.
bAlarm relay
Input
Output
DC voltage source
Temperature sensor

TOCII CA72TOC Identification
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2 Identification
2.1 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
•Measuringrange
• Outputs and communication
• Power supply
• Degree of protection
• (Permitted) ambient conditions
2.1.1 Product structure
Measuring range, adjustable
A 0.25 to 600 mg/l TOC
B 1 to 2400 mg/l TOC
C 2.5 to 6000 mg/l TOC
D 5 to 12000 mg/l TOC
Y Special version according to customer specification
Sample transfer
1 1 measuring point
2 2 measuring points; time controlled
3 2 measuring points; external controlled
Operation mode
A Batch mode
Power supply
0 230 VAC, 50 Hz
1 115 VAC, 60 Hz
2 115 VAC, 50 Hz
3 230 VAC, 60 Hz
9 Special version according to customer specification
Sample preparation
A 1 x PA-2 PVC, 1 to 8 m3/h (4.4 to 35 gpm) wastewater (not with
CA72TOC-*2*********)
B 1 x PA-3 PVC, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with
CA72TOC-*2*********)
C 1 x PA-9 PP, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with
CA72TOC-*2*********)
D 2 x PA-2 PVC, 1 to 8 m3/h (4.4 to 35 gpm) wastewater (not with
CA72TOC-*1*********)
E 2 x PA-3 PVC, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with
CA72TOC-*1*********)
F 2 x PA-9 PP, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with
CA72TOC-*1*********)
Y Special version according to customer specification
Language instrument, documentation
1German
2 English
CA72TOC- Order code

Identification TOCII CA72TOC
8Endress+Hauser
!Note!
To complete your order code, simply add the optional features to the end of order code. If you have
any questions, please contact your local sales office.
2.2 Scope of delivery
The scope of delivery comprises:
• 1 analyzer CA72TOC
• Accessories for leak check
• Tool kit to remove the glass ball and the media
• Accessories for acid filter
• Kit for commisioning of stripper and separation chamber
• Accessories for combustion furnace maintenance
• Accessories for connection and draining
• 1 canister 5 liter
• 2 canisters 2 liter
•3coversforcanisters
• Key for door lock
• Connection box EMV
• Measuring glas 10 ml
• Sponge
• Safety glasses
• Gloves, acid-proof and base proof
• Protective gloves, heat-resistant
• Silicone grease
• Operating Instructions
If you have any questions, please contact your supplier or your local sales center.
2.3 Certificates and approvals
Declaration of conformity
The product meets the requirements of the harmonized European standards. It thus complies with
the legal requirements of the EC directives.
The manufacturer confirms successful testing of the product by affixing the 4symbol.
Carrying gas (optinal, select one option only)
E1 CO2-scrubber
E2 CO2-scrubber + compressor
Analyzer mounting (optinal, select one option only)
F1 Wall mounted
F2 Stand
Accessory mounted (optinal, multiple selection possible)
G1 Sample predilution
G4 Heated salt trap
G5 Pipe back flushing
G6 Standby mode PA-2/-3 failure
G7 Sample valve for aggressive media
G8 2-channel sample valve for aggressive media
Accessory enclosed (optinal, multiple selection possible)
H1 230 VAC furnace conditioning station (not with CA72TOC-***1******* and not with
CA72TOC-***2*******)
H2 115 VAC furnace conditioning station (not with CA72TOC-***0******* and not with
CA72TOC-***3*******)
H3 Standard furnace (not with CA72TOC-********G4**)
H4 Furnace for heated salt trap

TOCII CA72TOC Installation
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3 Installation
3.1 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. Keep the damaged products until the matter
has been settled.
• Check that the order is complete and agrees with your shipping documents.
• The packaging material used to store or to transport the product must provide shock protection
and humidity protection. The original packaging offers the best protection. Also, keep to the
approved ambient conditions (see "Technical data").
• If you have any questions, please contact your supplier or your local sales center.

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3.2 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)
a0012435
Fig. 1: Dimensions
400 (15.8)
600 (23.6)
785 (30.9)
1010 (39.8)
1558 (61.3)
mm (inch)
50
(1.97)

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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 CO2
• < 3 ppm hydrocarbons
• The pressure must be 2 bar (29 psi) constantly.
• The pressure tolerance is ±5 %.
• The compressed air volume is 650 to 750 cm3/min (1.37 to 1.6 ft3/hr).
• If compressed air is supplied in the building, the pipe must be fitted with a CO2scrubber (infeed
pressure 4 to 10 bar (58 to 145 psi) and a pressure regulator.
• Connection: 4/6 mm DN
The water is connected via a 6/8 mm DN or G3/8 coupling. The pressure must be between 2 and
4 bar (29 to 58 psi) (for version with "sample predilution": 3 ±0.2 bar (43.5 ±3 psi)).
3.2.3 Environment
• The analyzer requires a drain beneath the device. Use a 6/8 mm PTFE drain pipe. No
backpressure should form in the drain.
• An exhaust gas connection is required in enclosed spaces. Halogens or other vapors may not build
up in this area. No backpressure should form in the 4/6 mm exhaust gas tube.
• Ambient temperature range: 5 to 35 °C (41 to 95 °F)
• Humidity: 10 to 90 %, non-condensating
• It should be possible to access the analyzer from the front and rear.

Installation TOCII CA72TOC
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3.3 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.
3.3.1 Mounting sequence
1. Mount the analyzer on the base frame, a bench or in the pivoting frame.
2. Mount the EMC junction box (right-hand side of device).
3. Mount the reagent tray under the analyzer.
4. When using the "sample predilution" option, screw the two holders for the calibration
standards onto the left-hand side of the device.
5. Mount the vent on the sample conditioning system (only for PA-2 / PA-3 or PA-9).
6. Connect the media (see the "Connecting the media" section).
7. Establish the electrical connections (see the "Wiring" section).
3.3.2 Wall mounting with a pivoting frame
In the "Wall-mount" version, the analyzer is mounted to the wall with a pivoting frame.
a0014227
Fig. 2: Pivoting frame for wall-mounting
All bore holes for wall-mounting have a diameter of 8.5 mm (0.33").
740 (29.1)
15 (0.59)
15
(0.59)
790 (31.1)
30
(1.18)
25
(0.98)
600 (23.6)
1200 (47.2)
30
(1.18)
mm (inch)
1020 (40.2)

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3.3.3 Mounting on a base frame
In the "Base frame" version, the analyzer is mounted on a base frame.
a0013913
Fig. 3: Mounting on a base frame
3.3.4 Connecting the media
a0012643
Fig. 4: Connections on the left side panel
1 Power cable
2 Gas outlet
3 Gas connection
4 Water connection
5 Bypass rinse water
6 External grounding
7 Standard C2 connection
8 Standard C1 connection
9 Acid connection
10 Condensate drainage
11 Sample supply
12 Sample drainage
812 (32.0)
620 (24.4)
620 (24.4)
mm (inch)
1
2
3
4
5
67
8
9
10
11
12

Installation TOCII CA72TOC
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Sample supply
Sample is supplied via a 3/8" connection on the left side panel (item 11).
!Note!
Additional connections are required if sample conditioning takes place (see instructions for sample
conditioning).
Analyzer sample drainage
Sample is drained off unpressurized via a DN 6/8 mm hose connection (compression fitting) on the
left side panel (item 12) into an open channel or pipe. Route the hose in such a way that
backpressure cannot form.
Condensate drainage
Condensate is drained off via a hose gland (PE, DN 1.6/3.2 mm, scope of delivery) on the left side
panel (item 10).
Acid connection
Place the acid cistern in the reagent tray. Connect the acid hose to the left side panel (item 9).
Connecting the standards
If the analyzer is fitted with a predilution system, place the standard containers in the holder on the
left side panel.
If the analyzer is not fitted with a predilution system, place the standard containers in the reagent
tray.
Connect the standards to the left side panel (C1 to item 8 and C2 to item 7).
Gas outlet
Gas escapes via a hose gland (DN 4/6 mm) on the left side panel (item 2).
Sample supply Inlet (mm / inch) Outlet (mm / inch)
PA2 40 / 1.57 50 / 1.97
PA3 20 / 0.79 32 / 1.26
PA9 20 / 0.79 32 / 1.26

TOCII CA72TOC Installation
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3.3.5 Preparing the chemicals
#Warning!
Accidents with chemicals can kill, blind, burn, or damage lungs. Many chemicals are poisonous or
corrosive; some are explosive, by themselves or in combination. Others are hazardous because they
can be absorbed easily through skin or the respiratory system. When working with any chemicals,
always observe the precautions in the section "Precautions regarding use of chemicals".
The analyzer requires the following chemical solutions:
• Stripper solution
Nitric acid HNO3(CAS: 7697-37-2) conc. 25 %
This acid is used to acidify the sample. In this way, the carbonate ion CO3is converted to CO2
and the dissolved CO2is removed from the solution (TIC stripping).
• Parent solution
Potassium hydrogen phthalate (KHP (CAS: 877-24-7)) with a concentration of 5 000 mg TOC/l
This parent solution for calibrating and adjusting the analyzer is used as a diluted standard in the
measuring range from 0 to 600 mg TOC/l. In the event of high KHP concentrations and sample
acidification (pH < 2.5), there is the risk of KHP precipitating in the solution.
• Parent solution
Citric acid (CAS: 5949-29-1) with a concentration of 100 000 mg TOC/l
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.
Before you specify the concentrations of the standard solutions, determine what concentration
range the device should measure. The most common concentrations should be covered by the
standard solutions.
Please note, however, that there should be a concentration ratio of between 1:4 and 1:20 between
the two standard solutions.
If a limit value is to be monitored, it makes sense for the concentration of the standard to correspond
to the concentration of a limit value as this guarantees maximum precision when monitoring.
!Note!
Please note that no measurement method can provide accurate measurement results over a span
greater than 1:30.
Example:
20 and 200 mg/l should be selected here as the standard solutions. The system can then measure
accurately in the range from 10 to 300 mg/l (taking the measuring range of the system into
account). A higher measured value deviation can be expected below a concentration level of
10 mg/l and above a concentration level of 300 mg/l.
Concentration to be measured: 3 to 300 mg/l
Most frequent concentration: 50 to 150 mg/l
Limit value to be monitored: 200 mg/l

Installation TOCII CA72TOC
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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.
• Never prepare chemicals on your own. You may need assistance in the event of an accident. For
this reason, always make sure that someone is close-by. Only prepare chemicals in a properly
equipped laboratory.
• When preparing chemicals always wear protective goggles, rubber gloves and a rubber apron. In
addition, wear a dust mask or face shield when working with fine-powder chemicals.
• Chemicals or solutions that are used with the analyzer (or another process analysis device) should
never be inhaled, tasted or swallowed.
• When preparing solutions, you must always label the containers appropriately, indicating the
contents and the date of preparation. Dispose of unlabeled or expired solutions in accordance with
local regulations and guidelines.
• Some chemicals are very reactive when combined with other substances or dissolved in water
and cause explosions, fire or heat to occur, or dangerous gases, foams or sprays to be released.
Avoid the risk of dangerous accidents occurring: If you do not know how certain chemicals react,
make sure you do not mix them with other substances. Never mix chemicals that are known to
react severely.
Reagent quality
!Note!
Reagent quality can affect the accuracy of measurements. For this reason, follow the steps outlined
below to ensure reagent quality.
• For 10, 100, and 500 mg/l units, use the best grade of reagents. For 1,000, 5,000, and
10,000 mg/l units, ordinary commercial grade acids and persulfate are suitable. For the KHP
calibration standard, use reagent grade or better for all units. For the 1,000, 5,000 and
10,000 mg/l units, you can experiment with quality once you have established repeatability, and
as long as the results are not affected. Lower grades of acid and persulfate may be acceptable.
• Rinse all glassware and plastic containers thoroughly with deionized water. For best results,
acid-wash and rinse them again before use.
• Use good scales and weigh the standard as accurately as possible before mixing. Keep containers
closed to prevent contamination and deterioration.
• Accurate preparation of the calibration standard is essential for accurate calibration of the
analyzer. Inaccurate preparation of the standard will result in an erroneous calibration, which in
turn will yield worthless results.
• The KHP calibration standards for 10 and 100 mg/l deteriorate rapidly in solution. Keep
containers closed when not in use, and store in a cool place (such as a refrigerator). Heat and
exposure to air can ruin sensitive solutions quickly.
Preparing potassium hydrogen phthalate
"Caution!
Potassium hydrogen phthalate (KHP) can irritate the skin and cause problems with the eyes or
respiratory channel. Do not inhale the powder and do not attempt to ever swallow any of the
solution prepared.
Shelf life: Relatively stable, depending on the concentration. (Stability decreases with decreasing
concentration; refrigeration is recommended.)
Concentrations: Depends on the application.

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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 H2SO4
(4molar) (CAS: 7664-93-9) and top up the mixture with water until the 1-liter mark is reached. Stir
the solution once more. Label the container, indicating the contents and the date of preparation.
The solution with a concentration of 5,000 mg/l is stable (particularly when stored in a cool dark
place). It is recommended to perform serial dilutions on the basis of a standard substance of
5,000 mg/l to reduce the concentrations if needed. Example:
• If 10 ml of a solution with a concentration of 5,000 mg/l is diluted with 90 ml deionized water,
this results in a concentration of 500 mg/l.
• If 10 ml of a solution with a concentration of 500 mg/l is diluted with 90 ml deionized water,
this results in a concentration of 50 mg/l.
• If 10 ml of a solution with a concentration of 50 mg/l is diluted with 90 ml deionized water, this
results in a concentration of 5 mg/l.
Serial dilution is the preferred method to create lower concentrations instead of diluting 1 ml of the
5,000 mg/l solution with 99 ml deionized water. The latter method can result in measurement
errors.
"Caution!
Please note the following:
• Storable parent solutions with concentrations of 1,000 and 5,000 mg/l are relatively stable for
several weeks at room temperatures. Parent solutions must be stored in cool dark place.
• In the case of a solution with a concentration of 10 mg/l, on the other hand, the quality starts to
deteriorate at room temperature within 3 to 5 days. To give the KHP standard solutions greater
stability 4 ml H2SO4(4 mol) can be added to one liter (has a shelf life of up to 4 weeks).
• If parent solutions with a high KHP content acidify, there is the risk of the KHP precipitating.
• Make sure to keep the container with the crystalline KHP sealed at all times. If the crystalline KHP
comes into contact with the air, it absorbs water very quickly and must be dried before use.
Otherwise you will get inaccurate measurements since the concentration of carbon is lower in the
hydrous salt. KHP that has come into contact with air must be dried for one hour at 105 °C
(221 °F).
mg/l carbon g KHP Volume
5,000 10.627 1 l
1,000 2.1254 1 l
500 1.0627 1 l
100 0.21254 1 l
10 0.021254 1 l

Installation TOCII CA72TOC
18 Endress+Hauser
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.
• Wear protective goggles, gloves and protective clothing.
• Always add acids to water, not vice versa.
Shelf life: Storable parent solutions with concentrations of 100,000 mg/l are stable for 6 months
if stored in a cool, dark place at 4 to 8 °C (40 to 46 °F). Prepared standard solutions must be used
within four weeks even if stored in a cool, dark place.
Concentrations: Depends on the application.
Material:
• 1-liter volumetric flask
• Citric acid monohydrate C6H8O7& H2O (purity: p.a.)
• Nitric acid HNO3(65 %, purity: p.a.)
Procedure:
For an organic carbon solution with a concentration of 100,000 mg/l, dissolve 291.6 g of citric acid
monohydrate in 500 ml of deionized water in a 1-liter volumetric flask (other concentrations of the
solution are listed in the table below). Carefully add 55.0 ml (77.0 g) of nitric acid. Once the
chemicals have dissolved, top up the mixture with water until the 1-liter mark is reached. Stir the
solution once more. Label the container, indicating the contents and the date of preparation.
The solution with a concentration of 100,000 mg/l is stable (particularly when refrigerated). It is
recommended to perform serial dilutions on the basis of a standard substance of 100,000 mg/l to
reduce the concentrations if needed. Example:
• If 10 ml of a solution with a concentration of 100,000 mg/l is diluted with 90 ml deionized water,
this results in a concentration of 10,000 mg/l.
• If 10 ml of a solution with a concentration of 10,000 mg/l is diluted with 90 ml deionized water,
this results in a concentration of 1,000 mg/l.
• If 10 ml of a solution with a concentration of 1,000 mg/l is diluted with 90 ml deionized water,
this results in a concentration of 100 mg/l.
Serial dilution is the preferred method to create lower concentrations instead of diluting 1 ml of the
100,000 mg/l solution with 99 ml deionized water. The latter method can result in measurement
errors.
mg/l carbon Citric acid in g Nitric acid in ml Volume
100,000 291.6 55.0 1 l
50,000 145.8 55.0 1 l
10,000 29.16 55.0 1 l

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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. Ideally, the strength of the
acid in the feeder tank should be set in such a way that the system can regulate in both directions,
but the regulation range should be higher for higher volumes of acid dosed.
Regulation aid:
The acid feeder is typically in the region of a few % acid. The aim should be to achieve a feed rate
of 2 to 5 % for pump P3 (the current feed rate can be read in the
PROGRAMMING/TEST/OUTPUT/PUMPS menu).
To set the acid concentration, an acid is prepared as follows as the starter point:
• Fill the acid hose
• Start measuring operation with a real sample
• Allow the acid dosing system to regulate
• Feed rate > 2 % < 5 %, note the acid concentration and use for future mixtures
• Feed rate < 2 % acid concentration, dilute preparation
• Feed rate > 5 % acid concentration, increase the concentration of the preparation
• Replace the contents of the acid hose
• Allow the acid dosing system to regulate, read off the feed rate
Use of other acids
• Nitric acid
Nitric acid does not form lyophobic salts in the strip chamber. The resulting nitrogen oxides in
the combustion gas are filtered out with an acid filter upstream from the IR detector.
• Phosphoric acid
Phosphoric acid is a low-volatility, odorless acid that generates practically no precipitate. After
combustion, substances are formed that are filtered out completely in the heatable salt trap.
• Sulphuric acid
Sulphuric acid is a low-volatility, odorless acid. When using sulphuric acid, precipitate can be
expected with alkaline earth metal ions. In addition to the sulfur dioxides, salts also occur as a
reaction product downstream from the furnace. These salts are easily removed in the heatable salt
trap. Gypsum can also occur if the water is very hard.
• Hydrochloric acid
Hydrochloric acid is a volatile acid with a pungent odor. Salts do not precipitate in the strip
chamber. During combustion, salts occur (heatable salt trap) as does HCl gas, which is absorbed
in the condensate.
3.4 Post-installation check
• After installation, check that all connections are tightly fitted and are leak-resistant.
• Check all hoses for damage.
Deionized water (ml) HNO325 % (ml) HNO3concentration
Increase concentration 500 + 125 5.0 %
+ 125 8.3 %
+ 125 10.7 %
+125 12.5 %
Dilute 500 +125 5.0 %
+ 500 2.8 %
+1000 1.5 %
+2000 0.8 %

Wiring TOCII CA72TOC
20 Endress+Hauser
4 Wiring
4.1 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.
4.1.1 Preparing to wire
#Warnung!
Before connecting the device, make sure that the line voltage matches the voltage indicated on the
nameplate.
The following versions are available:
• 115 V AC 50 Hz
• 115 V AC 60 Hz
• 230 V AC 50 Hz
• 230 V AC 60 Hz
#Warning!
Danger! Risk of electric shock! Disconnect the device from the power supply system (disconnect the
mains plug). 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.
#Warning!
Ensure that the analyzer is sufficiently grounded via the mains connection.
Condition: 50 V < R*Imax
Imax = is the maximum current above which the residual current circuit breaker is triggered.
R = the resistance between protective ground and device ground.
If these conditions cannot be ensured, the device must be grounded on site.
You must make the following connections:
• Alternating current connection via mains plug
• External grounding if necessary
• Analog 0/4 to 20 mA outputs
•Binaryoutputs
• Binary inputs
•RS-232
The signal connections are located in the EMC screening box on the right-hand side of the cabinet.
The connection for the external ground is located at the bottom on the left-hand side of the cabinet.