Metrohm 7010 TOC User manual

7010 TOC ANALYZER -USER MANUAL
1
Version: 1.12
Prepared: DC
Verified : FG
Checked: FS
Approved: DM
Issued: 28/09/2015

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7010 TOC ANALYZER -USER MANUAL
I N D E X
1SAFETY PRECAUTIONS AND HAZARDS
1.1 General informations
1.2 List of warnings and potential dangers
1.3 Vent waste gas
1.4 Sample
1.5 UV lamps disposal
1.6 Analyzer general hazards
1.6.1 Electrical precautions and hazards
1.6.2 Operating precautions and hazards
1.6.3 Chemical and waste gas hazards
2INTRODUCTION
2.1 Analyzer description
2.2 Applications
2.3 Fast Loop Reservoir
2.4 Liquid enclosure components
2.4.1 Peristaltic pumps
2.4.2 Scrubber
2.4.3 UV reactor (UVR) + UV Scrubber
2.4.4 U-Tube
2.4.5 Glass condenser
2.4.6 Dryer
2.4.7 By-pass Valve
2.5 Electrical enclosure components
2.5.1 Copper filter
2.5.2 Sodalime filter
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9
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10
10
11
12
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19
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7010 TOC ANALYZER -USER MANUAL
2.5.3 Pump motor
2.5.4 Air compressors
2.5.5 Pressure regulator ,capillary and flowmeter
2.5.6 NDIR
2.5.7 User connections
3INSTALLATION
3.0 Unpacking and inspecting
3.1 Analyser moving
3.2 Location and mounting instruction
3.3 PRECOMMISSIONING
3.4 Electrical connections
3.4.1 AC Power connections
3.4.2 Analog output
connections
3.4.4 Relay A/B
3.4.5 Digital input/output
3.4.6 Levels
3.4.7 External dilutor supply
3.4.8 Fuses
4USER INTERFACE
4.0 User instructions
4.1 Main Page
4.2 Main page +process values
4.3 Calibration page
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29
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30
31
31
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32
33
34
34
35
36
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7010 TOC ANALYZER -USER MANUAL
4.3.1 Zerogas
4.3.2 Liquid Zero
4.3.3 Manual Calibration
4.3.4 Run autocal
4.4 Timing page
4.5 General setup page
4.6 Datalogger pag
4.7 Dual stream configuration
4.8 Dual range option
5MAINTENANCE
5.1 Pump tubing replacement
5.2 Copper wool replacement
5.3 Sodalime replacement in sodalime filter
5.4 UVR tubing's connection replacement
5.5 UV lamps replacements
5.6 Fuses replacement
6PREPARATION OF THE CHEMICALS
6.1 Preparation of the TOC standard solution
6.2 Preparation of the COD standard solution
6.3 Preparation of the Persulphate solution
6.4 Preparation of the Acid solution
6.5 Preparation of reducing solution
6.6 Preparation of the Cleaning solution
6.7 Preparation of TC Reagent solution
7ANALYZER SHUT DOWN
APPENDIX Optional Configurations
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51
52
53
55
56
59
61
63
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1.0 SAFETY PRECAUTIONS AND HAZARDS
1.1 General informations
Metrohm Applikon shall not be liable for errors contained herein and/or for any incorrect use of the analyser. The department head and the
operators of analyzer must be sure to read and observe the following instructions and to apply all national or local regulations and laws regarding
health and safety of the workfare.
Use, maintenance and service of this analyser are allowed only by qualified personnel fully trained on the analyzer’s operation.
This personnel should be physically and mentally fit and not under the effect of alcohol or/and drugs.
When the analyzer is not used it should be protected from intentional or unintentional powering on, using a proper circuit breaker.
Before to proceed with analyzer installation, please read through and fully understand this instruction manual to ensure proper operation. Pay
attention to all caution and dangers labels present on the analyzer and all caution and danger statements written in this manual. For analyzer
installation and use, please refer carefully to all information and recommendations present in this manual.
Failure to do so and non-observance of hazard or danger warnings could result in death or serious injury to the operators or damage to the
analyzer.
Before to use the analyser is necessary to check visually for damage of safety devices and report to your reference head even if they don’t cause
analyzer stop or malfunction.
All analyzer components are installed inside two metallic enclosures with doors equipped with a special key for opening, only endowed qualified
maintenance personnel. (ref. section 3.3). Opening the door for visual inspection is possible while the analyser is in normal operation, but only if all
the safety precautions and hazard and danger labels have been strictly observed.

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1.2 List of warnings and potential dangers
The table below is a list of hazard and danger warning labels that is possible to find on the analyzer and/or in this manual.
In the case of these labels, becoming damaged or unreadable they should be replaced with new ones by the analyzer owner.

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Hazard of eletrical shock
This symbol is used to warn of a hazard of severe electric shock or electrocution. All controls and maintenance on electrical
devices labelled with this symbol should be made by qualified personnel in accordance with national or local regulations.
Qualified personnel means a person who has been fully trained and has professional experience to avoid electrical hazards
and dangers. To avoid potential fatal electrical shock and/or analyzer damage always disconnect input power to analyzer before
servicing.
Concerned parts:
Fans
Air compressors
UV power supplies
Main power supply
UV lamps
Pump motors
Input terminal
Corcerned parts:
UV lamps
Pump motors
Air compressor
Hazard of chemical burns
This symbol is used to warn of a hazard of severe burns and seroius injury from dangerous chemicals. All handling and
manipulations during operation and maintenance of chemicals labelled with this symbol should be made by qualified personnel
in accordance with national or local regulations. Qualified personnel means a person who has been fully trained and has
professional experience to avoid chemical hazards and dangers. Before to proceed with the handling of chemicals or
operations read the material safety data sheets supplied with each chemical to ensure all the necessary precautions are taken.
Concerned parts:
UV lamps
Warning of general hazard
This symbol means that is necessary read this manual before proceeding with any service operation to know exactly how to
operate in a proper way. Only qualified personnel or personnel fully trained on analyzer use and maintenance is allowed to
proceed with service operations on the unit.
Hazard of thermic shock and burns
This symbol is used to warn of an hazard of thermic shock and burns. Some parts of the analyzer become extremely hot during
analyzer normal operations. Avoid skin contact with these surfaces and if necessary to service these parts be sure to
sufficiently enough to avoid burning. Always disconnect input power to analyzer before servicing these parts.
Corcerned parts:
Liquids enclosure
Reagents containers
Hazard of UV radiation
This symbol is used to warn of an hazard of ultraviolet radiation. It is obligatory to wear eye protection to operate with the UV
lamps labelled with this symbol.
Never look directly at a lighted UV lamp. UV radiation exposure can cause severe and permanent damage to skin and eyes.
Concerned parts:
TOC analyzer
Tab. 1-1: List of hazards and dangers

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Table 1-2 : List of materials used in 7010 TOC Analyzer
Pump tubings
Fittings
Connection tubings
GLS,U Tube,
Scrubber, Condenser
Halogens and sodalime filter body
Filter contents
UV lamps
Bypass valve
IR cell
Gas dryer tubing
Norprene,Tygon
Polypropylene
PFA
Glass
PVC, polycarbonate
Copper wool (halogens filter),
Sodalime (CO2 filter)
Quartz
Noryl, viton
Stainless steel
Nafion
1.3 Vent waste gas
Waste gases coming from analyzer oxidation process depend on the user’s sample composition. They are labelled on the external side of the
cabinet as VENT outlets. It is necessary to connect an extension tubing or to provide for safe venting to the atmosphere or to a classified safe
area.
1.4 Sample
Take appropriate precautions to avoid direct contact with sample stream.
It is responsability of the user to be aware of and take all precautions
regarding physical, chemical, radiation and/or biological hazards and
dangers coming from sample stream and/or sample vapours. It is also
responsibility of the user to be aware of potential hazards regarding the
chemical and physical compatibility of sample stream with the analyzer
materials.
1.5 UV lamps disposal
Used or replaced UV lamps contain a small quantity of mercury and they
must be disposed according with national or local environmental
regulations regarding hazardous and poisonus materials.

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1.6 ANALYZER GENERAL HAZARDS
1.6.1 Electrical precautions and hazards
In all electrical devices that are 230 VAC (or 115 VAC opt.) powered present hazards of
electrical shock or electrocution.
To protect all the personnel involved in analyzer use and maintenance, the doors of the two
analyser enclosures are equipped with a special key for opening.
If necessary to operate inside the electrical enclosure with the analyzer powered on, please
consider that this operation must be made only by qualified personnel in accordance with
national or local regulations. Qualified personnel means a person who has been fully trained
and has professional experience to avoid electricity hazards and dangers.
Service qualified personnel will receive the special key to open the electrical enclosure.
Before to service the analyzer or parts of that electrically powered, turn off all power to avoid risk
of electrocution.
To turn off power from an electrical device is necessary to interrupt the power line using a circuit
breaker or an isolating switch to be sure that there is no power in the area being serviced.
Users and qualified maintenance personnels must proceed as follows:
pay attention to electrical shock and/or electrocutions labels placed on the analyser
always isolate power before servicing the analyser
In case of loss of power the analyser stops and will automatically restart as soon as power is
restored.
WARNING: UV lamp power supply
reaches an ignition voltage up to 3000
volts; do not operate any service
activity without removing the
instrument power cord .
Analyser’s control circuitry is powered 24
Vdc and 12 Vdc. Inside the electrical
enclosure the lower level of protection
against direct contacts is IP2X. Analyzer
enclosures are IP54 (because of air fans
holes).
Protection against indirect contacts is
guaranteed by efficient grounding of all
isolated metal masses.
Grounding bar is located inside the
electrical enclosure, in upper left position
below the protection cover.
It will be user’s responsability to
check and garantee periodically the
perfect efficiency of analyzer’s
grounding.

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1.6.2 Operating precautions and hazards
HAZARD:
PREVENTIVE ACTIONS:
HAZARD:
PREVENTIVE ACTIONS:
HAZARD:
PREVENTIVE ACTIONS:
HAZARD:
PREVENTIVE ACTIONS:
Mechanical hazards caused by moving parts such as fans, pumps, motors and air compressors
To avoid risks the analyzer’s moving parts have been designed, built and located in a closed enclosure with a
special opening key. Where present inside the enclosures, these parts have protection covers to avoid any contact
and physical injury to users.
Hazards of burns caused by hot parts of UV lamps, motors and air compressors
To avoid risks, the analyser’s parts that become very hot to the touch have been designed, built and located in
closed enclosure with a special opening key. When present inside the enclosures, these parts have protection
covers and warning labels to avoid any contact and physical injury to users.
Hazard of poisoning caused by waste gas coming out from VENT line
Install the analyser in location of adequate dimensions and well ventilated.
Hazards of UV radiation exposure caused by UV lamps
To avoid risks, the analyser’s parts that produce UV radiation emissions have been designed, built and located in
closed enclosure with a special opening key. When present inside the enclosures, these parts have protection
covers and warning labels to avoid any contact and/or exposure and/or physical injury to users.

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Electrical equipments of input power and grounding must
comply the national or local regulations and laws.
Check that the source voltage to be used corresponds
with that requested by the analyser.
Check periodically the power cord as well as the analyser
grounding.
WARNING: UV lamp power supply reaches an ignition
voltage up to 3000 Volts; do not undertake any service
activity without removing the instrument power cord.
N TE :
Hazard of electric shock and/or electrocution in the
electrical enclosure
The analyser’s electric equipment complies with
EN 60204 requirements.
To avoid risks, the analyser’s parts that can cause
hazard of electric shock and/or electrocution have
been designed, built and located in a closed
enclosure with a special opening key. When
present inside the enclosures, these parts have
protection covers and warning labels to avoid any
contact and serious injury or death to users.
HAZARD:
PREVENTIVE ACTIONS:
HAZARD:
PREVENTIVE ACTIONS:
1.6.3 Chemical and waste gas hazards
The analyser has been designed, built and equipped to avoid risks caused by physical and chemical factors as noise, vibrations, radiations, dust,
waste gas etc.
Hazard of burns and poisoning caused by contact with dangerous chemicals
To avoid risks, the analyser’s parts that can cause contact with chemicals have been designed, built and located in
closed enclosure with a special opening key. Before to service the liquids enclosure, read the material safety data
sheets supplied with each chemical to take all the necessary precautions when handling. Wear eye protections,
gloves, mask and protective clothing if necessary.

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This manual provides general information regarding the principle of
operation and proper installation and operation of the 7010 TOC Analyser .
The analyser measures Total Organic Carbon in liquid samples using the
EPA approved method based on UV persulfate oxidation and detection of
generated carbon dioxide using a Non Dispersive Infrared analyser. This
method meets also the requirements of European ISO/CEN guidelines. The
analyser provides this measurements on liquid samples ranging from 0-5
mg/l to 0-20000 mg/l.
The analyser conforms to EPA, DIN, CE, ASTM and NAMUR regulations.
2.0 ANALYZER DESCRIPTION

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2.1 APPLICATIONS
The 7010 T C analyser continuously measures Total Organic Carbon
(TOC) in water.
It has been designed for the following applications:
Industrial waste water
Condensate and cooling water
Drinking and river water
Industrial water treatment plant inlet/outlet
For different applications or different aqueous matrices it is recommended
to contact your Metrohm distributor to verify your application with our
specialists.

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The analyser is assembled in two separated enclosures. The first one, called LIQUIDS enclosure , includes all the components involved in sample and reagent flows as well as
their mixing in sparging and oxidation stages. This enclosure is properly vented by a fan to allow good air refreshment inside the cabinet. The second one, called ELECTRICAL
enclosure , includes the main power supply, the carrier gas generation and flow adjustment devices, the controlleing PCB assembly and the infrared detector.
legend:
01) UV lamp power supplies
02) glass condenser
03) by-pass valve
04) condenser fan
05) dryer tubing
06) UV reactor
07) resample pump
08) sample pump
09) persulfate pump
10) phosphoric acid pump
11) auto pump
12) UV scrubber
13) U-tube
14) scrubber
15) drain
legend:
01) user connections
02) copper filter
03) pumps motor
04) pressure regulator +
flow capillary
05) sodalime filter
06) dryer +scrubber
capillary
07) flowmeter
08) check valve
09) carrier gas compressor
10) scrubber gas
compressor
11) fan
12) air filter
13) NDIR

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The sample is pumped by a peristaltic pump (08) to the inorganic scrubber (1 4)
afterd mixing with acid (usually phosphoric acid) pumped by a second peristaltic
pump (1 0) .
The inorganic removal is performed using ambient air provided by an internal air
compressor (1 0) . This first process lowers the pH of the sample and convert the
carbon carbonates to carbon dioxide. The carbon dioxide dissolved in water is then
driven out by the sample to the vent using compressed air.
The acidified and sparged sample is then pumped from the scrubber bottom to the
UV reactor (06) by the resample pump (07) , after mixing with a strong oxidizing
agent (usually sodium persulfate) pumped by a dedicated peristaltic pump (09) .
The presence of a strong oxidizing agent combined with high level UV radiation
causes the oxidation of organic compounds. The produced carbon dioxide is
driven to the gas-liquid separator (1 2) . The liquid sample is drained off while the air
that containing carbon dioxide goes to the infrared analyser (1 3) , passing in
sequence through a glass condenser (02) , gas drier tubing (05) and a halogens
filter (02) . These devices are present to prevent condensation and corrosion inside
the stainless cell of the IR. The carrier gas used for the oxidation and detection
stages is generated by a second internal air compressor (09) and is passed
through a sodalime filter (05) . The carbon dioxide free gas passes through a
pressure regulator (04) , a capillary tubing and a digital flowmeter (08) to reach
finally the UV reactor. All these devices are necessary to guarantee high precision
and stability of carrier gas flow as well as to control and be able to display the flow.
2.2 OPERATING PRINCIPLE
The water from the sample source (directly from the sampling point or through the optional
filtration unit) is fed to a sampling device mounted on the external left side of the analyzer
(ref. page 1 9) . This device drains the sample excess and is equipped with a level sensor
to check the sample presence. This device allows a good sample refreshment and will put
the analyzer in stand-by condition in case of loss of sample.
SODIUM PERSULFATE
CLEANING
ACID
SAMPLE

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SODIUM PERSULFATE
CLEANING
ACID
SAMPLE
TOC FLOW DIAGRAM

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SODIUM PERSULFATE
CLEANING
ACID
SAMPLE
REDUCING REAGENT
REDUCING REAGENT FL W D I AG RAM
legend:
01) UV lamp power supplies
02) glass condenser
03)by-pass valve
04) condenser fan
05) dryer tubing
06) UV reactor
07) resample pump
08) sample pump
09) persulfate pump
10) phosphoric acid pump
11) auto pump
12) UV scrubber
13) U-tube
14) scrubber
15) drain
X2) reducing reagent pump

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2.3 FAST LOOP RESERVOIR The external reservoir allows a fast circulation of the sample coming from the sampling point or from the
optional filtration unit.
Inside the fast-loop reservoir the sample is at atmospheric pressure and this allows the sample pump to
function with a constant delivery and no overpressure.In addition, the fast-loop reservoir is a useful extra
quantity of sample to avoid wrong alarms in case of a short loss of sample as well as eliminating air
bubbles coming from the sample line or from the cleaning cycle of the optional filtration unit.
The stainless steel drain tubing keeps a constant water level inside the container and allows a proper
sample circulation to avoid suspended solids accumulation.
The sample flow should be adjusted to have a constant sample overflow through the stainless steel tube.
Up to 3 level switches can be connected to the analyzer, e.g. Stream A,Stream B and dilution water. Two
of the switches are normally connected to the terminals that are found at the left hand side of the
analyzer. For a dual stream analyzer where dilution water is also required for one or both streams, the
third level switch is connected to the user connection inside the analyzer (see page 37).
For a single stream analyzer, in the event of a missing sample or dilution water stream for a period longer
than a preset time (normally set on installation to 30 s), an alarm - LOSS OF SAMPLE - is triggered and
the analyzer switches to Standby. When the missing sample or dilution water stream is reestablished, the
analyzer restartsautomatically with a conditioning cycle.
In the case of a dual stream configuration, if no Stream A is present then the analyzer will continue to
work only on Stream B until Stream A is reestablished, and vice-versa. If both streams are not present
then again the alarm LOSS OF SAMPLE is triggered and the analyzer switches to Standby.
If either or both streams are being diluted and the dilution water stream is missing, then jumpers found
alongside the internal Level 3 terminal can be used to make the analyzer work only on the undiluted
stream or switch to Standby if both streams are diluted, again giving the alarm LOSS OF SAMPLE.

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LIQUID ENCLOSURE