Thermo Scientific Orion 2120XP User manual

Thermo Scientific
Orion 2120XP Calcium
Hardness Analyzer
User Guide
263639-009 Rev. A 09-09

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1
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Table of Contents
Chapter I
GeneralInformation............................................ I-1
Introduction.............................................I-1
FeaturesandBenefits.......................................I-2
PrinciplesofOperation.....................................I-3
PrinciplesofCalibration....................................I-5
Double Known Addition (DKA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
OfflineCalibration.......................................I-6
FluidicsDiagram..........................................I-7
Glossary ................................................I-8
Two Channel Analyzer Configurations . . . . . . . . . . . . . . . . . . . . . . . . I-10
Chapter II
AnalyzerPreparation...........................................II-1
UnpackingtheAnalyzer ....................................II-1
Mounting and Plumbing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .II-2
SampleRequirements......................................II-3
ElectricalWiring..........................................II-4
SafetyRequirements .....................................II-4
Warning Labels and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II-5
WiringtheAnalyzer .......................................II-6
TerminalAssignments......................................II-8
Electrode Wiring Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II-9
Installation of Reagent and Diffusion Tubing . . . . . . . . . . . . . . . . . . .II-10
Installation of New Electrode Cables. . . . . . . . . . . . . . . . . . . . . . . . . .II-11
Installation of a New Calcium Electrode . . . . . . . . . . . . . . . . . . . . . . .II-12
InstallationoftheATCProbe...............................II-12
Installation of a New Reference Electrode . . . . . . . . . . . . . . . . . . . . . .II-13
Chapter III
AnalyzerOperation............................................III-1
Description of Basic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-1
DescriptionofKeypadIcons................................III-2
UseoftheSetupMode....................................III-3
SetupModeOverview.....................................III-5
Shutdown and Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . III-35

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Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Chapter IV
Calibration...................................................IV-1
CalibrationSetup ........................................IV-1
FlowCellOperation......................................IV-2
RinsingtheFlowCell.....................................IV-3
AirRegulation...........................................IV-4
Before Performing a DKA Calibration. . . . . . . . . . . . . . . . . . . . . . . . . IV-5
Performing a DKA Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-6
CalibrationAbortSteps...................................IV-10
CalibrationErrorCodes ..................................IV-11
Calibration At Custom Concentrations Using DKA . . . . . . . . . . . . . IV-13
SpanCheckProcedure....................................IV-14
Offline Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-15
Chapter V
AnalyzerMaintenance .........................................V-1
MaintenanceSchedule......................................V-1
WeeklyMaintenance.......................................V-1
MonthlyMaintenance......................................V-2
Yearly Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-5
Chapter VI
Troubleshooting ..............................................VI-1
DiagnosticsMode........................................VI-1
SlopeProblems..........................................VI-9
TroubleshootingMatrix...................................VI-11
Error/EventCodes.......................................VI-14
ResettingtheAnalyzer....................................VI-17
Serial Number and Software Revision . . . . . . . . . . . . . . . . . . . . . . . . VI-18
ServiceandRepair.......................................VI-19
Chapter VII
CustomerService.............................................VII-1
NoticeofCompliance. ...................................VII-1
WEEECompliance......................................VII-1
DeclarationofConformity................................VII-2
TermsandConditions....................................VII-3
Appendix .....................................................A-1
MountingDimensions .....................................A-1
ISEDefaultValues ........................................A-2
Specifications ............................................A-3
OrderingInformation......................................A-7
Recommended Consumables for Annual Operation . . . . . . . . . . . . . .A-10
PipetOperation..........................................A-11
PipetTechniques.........................................A-12

I-1
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Chapter I General Information
This user guide covers the operation, maintenance and troubleshooting for
the Thermo Scientific Orion 2120XP calcium hardness analyzer, which
offers unmatched reliability in analyzing calcium hardness from sodium
zeolite softener effluent and drinking water applications.
Monitoring the calcium hardness ion content to prevent boiler tube
scaling or to control water hardness in municipal water applications
requires a well designed and maintained system. The system must optimize
the fluidic design with the sensing technology to provide accurate and
precise results with an almost instantaneous indication of calcium hardness
concentration changes.
The 2120XP calcium hardness analyzer meets all of the criteria for accurate
and dependable calcium hardness monitoring and more. The 2120XP
analyzer incorporates innovative technologies that include:
• Premium electrodes
• Accurate and precise flow cell design
• Marquee help screen
• Pump-less reagent addition and DKA calibration system
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer
• Power
• Pulp and paper
• Chemical / petrochemical
• Municipal drinking water
• Zeolite softener effluent monitoring
• Water softening
• Blending applications
Introduction
Markets
Applications

General Information
I-2
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
The Thermo Scientific Orion 2120XP calcium hardness analyzer is ideal
for measuring and monitoring the critical calcium hardness levels in any
softener effluent or drinking water application. With limited maintenance
requirements and low reagent usage, the 2120XP analyzer can also be used
in remote monitoring applications.
• Measurement of calcium hardness in water using premium Thermo
Scientific Orion ion selective electrode (ISE) technology.
• Accurate and precise measurements in the range of 25 ppb to 500 ppm:
• Reliable measurements and a wide measurement range with
selectable resolution.
• Measures calcium ion activity in aqueous solutions quickly,
accurately and economically.
• Premium reference and sensing electrodes:
• Superior accuracy and stability over a wide temperature range.
• Advanced flow cell design with air stirring:
• Automatic sample handling and contamination control with no
moving parts.
• Patented scrolling marquee:
• Intuitive menu-driven digital user interface.
• Data log of previous measurements and calibration:
• View measurement, calibration and error history.
• Self diagnostics:
• Ease of maintainability.
• Password protection:
• Security and peace of mind for your operation.
• Auto-ranging electronics with an easy to read backlit LCD display:
• Analyzer determines the best range.
Features and Benefits

General Information
I-3
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
The sample enters the Thermo Scientific Orion 2120XP calcium hardness
analyzer and passes through the inlet valve, bypass/needle valve, inlet filter,
pressure regulator, flow meter and into the restrictor tubing. The sample
then passes through the flow cell manifold into a reagent bottle through
a diffusion tubing assembly where pH adjustment takes place. The pH-
adjusted sample then flows back through the manifold into the flow cell
as air is introduced from the air pump to ensure proper mixing and fast
response. The sample then flows into an atmospheric drain via the
diverter valve.
Principles of Operation
Safety Drain for
Reagent Overflow
Restrictor Tubing
Pressurizes Flow Cell
to Initiate Siphoning
Flow Meter
Valve Positions
Calibration Mode - PUSH
Sample/Measure Mode - PULL
Analyzer
1 2 3 4 5
Power
4-20mA Output
Air Pump
F
l
ow Meter
Inlet Valve
Bypass / Needle
Valve and Filter
Regulator
Valve
Reference Solution
Calibration
Port
Sense
REF TEMP
Flow Cell Block
Calibration Level
Air Filter
Reagent
Reagent Bottle
Diffusion Tube
Reagent Manifold
Fluid Path
Fluid Restrictor Tubing
Electric
Air Path
Reference Solution Path
Reagent Overflow Path
Diffusion Tubing
K E Y
Main Feed
Air Inlet
Measure Level
Drain
Check
Valve
Sample
Valve
Valve
ve
al
Val
Cal
Figure I-1
2120XP Schematic

General Information
I-4
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
The sensing electrode responds logarithmically to changes in the calcium
ion concentration. This response is described by the Nernst equation:
E = Eo+ 2.3 (RT/nF) log (C/Ciso)
Where:
E = measured electrode potential, mV
Eo= potential, when C equals Ciso, mV
R = ideal gas constant
T = temperature of sample, degrees K
n = valence of ionic species (+2 for calcium ion)
F = Faraday’s constant
C = effective calcium ion concentration (activity)
Ciso = concentration (activity) of calcium ion where potential E is
temperature independent (isopotential point)
The above equation indicates that the measured potential varies with both
temperature and the concentration of the ion of the interest. In order to
eliminate error caused by fluctuations in sample temperature, the 2120XP
analyzer microprocessor constantly updates temperature corrections from
data supplied by the ATC probe.
From the Nernst equation, the theoretical response of a calcium ion
selective electrode to a ten-fold change in concentration at 25 °C is
+29.58 mV. This is referred to as the electrode slope (S). Most electrodes,
however, do not exhibit a theoretical slope. Therefore, the analyzer is
calibrated to determine its actual value. Two standards are used to provide
information necessary for the microprocessor to compute the actual slope
and E0for use during sample analysis.
In order to eliminate interference from hydrogen ions, which can become
significant when measuring low levels of calcium hardness, the 2120XP
analyzer adjusts the sample pH. This pH adjustment is accomplished by
the patented passive-diffusion process wherein the sample passes through
a length of tubing contained in the reagent bottle. The reagent diffuses
through the tube wall and mixes with the sample, which adjusts the sample
pH to below 4.

General Information
I-5
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Principles of
Calibration
Calibration procedures for analytical instruments are important and must
be performed carefully. The calibration procedure used in the Thermo
Scientific Orion 2120XP is a variation of Double Known Addition (DKA)
using advanced electrode and flow cell technology in combination with the
passive diffusion system. This method has the distinct advantages of being
fast, easy, and accurate.
Before calibration begins, the diverter valve is pushed in to divert flow from
the measure drain, allowing the flow cell to fill.
At the beginning of the DKA calibration the actual concentration in the
sample is unknown. The analyzer measures the potential (Es) and stores
this value in the microprocessor. A known amount of standard 1 solution
is added to the flow cell, which increases the concentration (Cs) with a
corresponding known amount (dC1). During this process, air is pumped
into the flow cell, thoroughly mixing sample and standard in a closed-
loop system. The new potential (E1) is measured and stored automatically
when stability is reached. Adding standard 2, preferably 10 times more
concentrated than standard 1, increases the concentration (dC2) in the
sample reservoir. Again, the new potential (E2) is measured and stored
when the reading is stable. Now, we have the following three unknowns:
Es=Eo+ S(Ts/298.15) log (Cs/Ciso)
E1=Eo+ S(T1/298.15) log [(Cs+ dC1)/Ciso]
E2=Eo+ S(T2/298.15) log [(Cs+ dC1+ dC2)/Ciso]
S is the Slope at 25 °C (298.15 K)
T is the temperature in Kelvin, measured when the potential E is measured.
Es, E1, E2have been determined during the calibration procedure. The
microprocessor solves these three equations, to obtain the values of S
and Eo. The calibration result is stored for use during online monitoring
to convert the measured potential and temperature in the sample into
concentration values in either ppm or ppb.
When the calibration is complete the flow cell drains as the sample flow
returns. The flow cell volume returns to the measurement level. After
allowing approximately 30 minutes for concentrated calibration solution
to be flushed from the system, the 2120XP analyzer can begin sample
measurement again.
In addition to Double-Known Addition (DKA), the 2120XP analyzer also
allows the operator the ability to perform an offline calibration.
Double Known
Addition (DKA)
Figure I-2
Flow Cell Volume for DKA

General Information
I-6
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
The offline calibration feature of the 2120XP analyzer allows the operator
to adjust the analyzer to values determined by alternate methods used in
their laboratory such as elemental spectroscopy and ion chromatography.
The offline calibration is essentially a one point calibration. To perform an
offline calibration, a sample is taken from the bypass of the analyzer; the
sample concentration value is stored in memory; the sample is analyzed
by an alternate method of choice; the previously stored reading is adjusted
to the lab method result; and the analyzer is then returned to the analysis
mode. The term “offline calibration” refers only to the fact that a sample
from 2120XP analyzer bypass is taken “offline” for laboratory analysis; in
fact, no downtime is experienced during the procedure and the analyzer
remains online throughout.
Offline Calibration

General Information
I-7
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Fluidics Diagram
Scrolling Marquee
LCD Display
Warning Icon
Mode Indicator
Mounting
Hole
Keypad
Flow Cell
Reservoir
Siphon Tube
Flow Cell Block
Inlet Valve
Reagent
Bottle
Adapter
Assembly
Pressure
Regulator
Status Indicators
Flow Meter
Calibration Port
Reference
Filling
Solution
Restructor
Tube
Assembly
Air Pump
Bypass/Needle
Valve
Inlet Filter
Reagent
Manifold
Diverter Valve
Diffusion Tubing
Assembly
Reagent Bottle
Figure I-3
Fluidics Diagram

General Information
I-8
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Refer to Figure I-3.
Inlet Valve – Accepts the sample stream via 1/4 inch NPTF connector. The
operator must supply the sample with a pressure between 14 and 100 psig.
Inlet Filter – 60 micron stainless steel filter traps particulate matter in the
sample stream.
Bypass/Needle Valve – Used to redirect flow in the bypass system.
Pressure Regulator – Adjusts flow on the incoming sample stream.
Flow Meter – Measures the sample flow rate.
Check Valve – Prevents the backflow of sample.
Restrictor Tube Assembly – Used in conjunction with the pressure
regulator to lower downstream pressure.
Reagent Manifold – Directs the sample flow in and out of the reagent
bottle assembly.
Reagent Bottle Adapter Assembly – Connects the reagent bottle assembly
to the manifold.
Diffusion Tubing Assembly – Semi-permeable tubing through which
reagent diffuses into the sample.
Reagent Bottle – Contains formic acid reagent that lowers the sample pH
to below 4.
Flow Cell – Contains the calcium sensing electrode, reference electrode and
ATC probe.
Diverter Valve – Allows the flow cell reservoir to fill during calibration by
forming a closed-loop system.
Calcium Electrode – Senses calcium ions in the sample stream and
produces an electrical potential dependent on sample concentration.
Reference Electrode – Provides a constant reference potential and
completes the measurement circuit.
Reference Electrode Filling Solution Bottle – Provides constant flow of
electrolyte solution through the reference electrode for maximum stability.
Glossary

General Information
I-9
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
ATC Probe – Measures the sample temperature and inputs the data to the
microprocessor for automatic temperature compensation (ATC).
Calibration Port – Allows introduction of standards to the sample reservoir
during calibration.
Air Pump – Used to mix the sample during both measurement
and calibration.
LCD Display – Provides digital readouts of concentration, temperature,
millivolts and error codes.
Keypad – Consists of five mode keys, four prompt indicator lights, two
scroll keys and one key for entering data. Mode and error indicators are also
incorporated on keypad.
Status Indicator – Two LED lights that illuminate according to current
status of the analyzer.
Green Light: Indicates that system is in correct working condition.
Yellow Light: Indicates a warning, system in hold or that
maintenance is required.
Red Light: Indicates that something is seriously wrong.
Note: When either the yellow or red LED is lit, there may be an entry in
the diagnostics mode that indicates the error. The logging feature must be
initiated in the setup mode. Refer to Chapter III, Use of the Setup Mode
for instructions.

General Information
I-10
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
A pH/ORP module or conductivity module can be added by the operator
to the second channel of the Thermo Scientific Orion 2120XP calcium
hardness analyzer for the ultimate flexibility in measurement capabilities.
The 2100 series pH/ORP and conductivity analyzers provide accurate and
reliable measurements in ultra pure water as well as the harshest industrial
environments. Combined with decades of superior Thermo Scientific
Orion sensor technology, our systems provide rapid results with
complete stability.
Cat. No. Description
2100PH2 Second channel module for pH/ORP
2100CD2 Second channel module for conductivity
When a pH/ORP module or conductivity module is installed on the
second channel of the 2120XP calcium hardness analyzer, refer to the
Thermo Scientific Orion 2100 Series pH/ORP Analyzer and Conductivity
Analyzer User Guide for detailed instructions on operating the pH/ORP or
conductivity analyzer. Visit www.thermo.com/processwater to download
any of the 2100 series analyzer user guides.
Two Channel Analyzer
Configurations

II-1
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Chapter II Analyzer Preparation
Thermo Scientific Orion analyzers are assembled, tested and packaged with
great care. Refer to Figure II-1.
Report any obvious damage of shipping container to carrier and hold for
inspection. The carrier (not Thermo Fisher Scientific) is responsible for any
damage incurred during shipment.
1. Open the outer box. Remove the top two foam corner support pieces.
2. Open the inner box. This box should contain the analyzer and ATC
temperature probe, calcium electrode box, reference electrode box,
calcium standard solutions kit (two 2 oz bottles of 191 ppm CaCO3
standard and two 2 oz bottles of 1920 ppm CaCO3 standard), the
options kit and user guide CD.
3. Remove the cardboard retaining shell by sliding it over the entire
mounting board and the analyzer.
4. Carefully remove the entire mounting board with analyzer from the
inner box.
Note: Do not lift or pull the analyzer by the fluidics or the
electronic components.
5. Unbolt the analyzer from the mounting board by removing the four
mounting bolts with a 9/16 wrench. These bolts may be discarded.
6. Carefully place the analyzer at a convenient location until proper
installation can be completed.
Unpacking the
Analyzer
Figure II-1
Unpacking the Analyzer

Analyzer Preparation
II-2
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Refer to the Appendix, Mounting Dimensions section.
Warning: Do not connect power prior to the mounting and plumbing of
the analyzer.
• Select a site for the analyzer that allows it to be permanently bolted
with ample height for atmospheric drain operation. Be sure that there is
ready access to the electronic controls, calibration port and electrodes.
• A clearance of 15 inches (about 40 cm) must be allowed above the
flow cell calibration port. Insert the pipet vertically (not angled) during
the calibration.
• The analyzer location must permit connections to a sample line, drain
and AC power supply and any connections for output devices.
• The analyzer should be mounted as close to the sampling point as
possible. This ensures the fastest possible response to a changing sample
condition. Refer to the Appendix, Sample Conditions section.
• For proper flow cell operation, the analyzer must be installed straight
and level upon its mounting location. Failure to level the analyzer may
cause poor siphoning in the flow cell.
1. Prepare the mounting holes. Carefully lift the analyzer and bolt it into
place. Do not lift the analyzer by holding on to any of the plumbing or
fluid handling components.
2. Connect a waste line to the outlet of the analyzer, which is 3⁄4 NPT
male. The waste line should be connected to a drain of sufficient
capacity, 0.5 inch (1.27 cm) OD is recommended.
3. Connect a sample line to the inlet of the analyzer, which is 1⁄4 NPT
female. It is recommended that a shutoff valve be installed at the
sampling point.
4. The analyzer must be mounted and leveled vertically for proper
operation.
Mounting and
Plumbing Instructions
Recommendations
Instructions

Analyzer Preparation
II-3
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Sample Requirements Additional information is listed in the Appendix, Specifications section.
Sample inlet connection – 1/4” NPTF. If particulate matter is present in
the sample, pre-filtration is necessary. The 60 micron stainless steel filter
located after inlet valve will remove moderate amounts of particulates.
Flow rate – 40 mL/minute (nominal).
Pressure – 8 to 100 psig. Consult Technical Support for details on sample
handling if the pressure is outside of this range.
Temperature – Temperature must be between 5 and 40 °C.
Calcium level – Calcium levels are read directly in ppb or ppm, when
calibrated with Thermo Scientific Orion calcium standards 1 and 2.
Sample alkalinity – Sample alkalinity should be less than 250 ppm CaCO3
equivalent. For higher sample alkalinity, contact Technical Support.

Analyzer Preparation
II-4
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
The warning icon highlights important information that should be strictly
followed when using the analyzer for your own safety. Failure to follow
these instructions may result in injuries.
Warning: Read and observe the following safety recommendations.
• Prior to wiring, a switch or circuit breaker for disconnecting the
analyzer from power supply should be installed.
• The switch should be in close proximity to the analyzer and with
easy reach of the user.
• The switch should be marked as the disconnecting device for
the analyzer.
• To reduce the risk of shock hazard, disconnect the power prior to
opening the analyzer.
• Before connecting the analyzer to the main, make sure that the voltage
lies within either range: 85 to 132 V, 200 mA or 170 to 264 V,
100 mA; 50 to 60 Hz AC.
• Cutting off the power by disconnecting power source will not reset the
analyzer. This analyzer incorporates a non-volatile memory and will
maintain calibration and settings after power failure. Battery power is
supplied to the display for the date and time functions.
• If a repair is required, or to arrange Return Material Authorization, call
Technical Support or contact your local authorized dealer.
• Installation and wiring of the analyzer may only be carried out in
accordance with applicable local and national codes per this user guide.
• Be sure to observe the technical specifications and input ratings.
Electrical Wiring
Safety Requirements

Analyzer Preparation
II-5
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Warning Labels
and Locations
Warning: The following section provides important information that
should be strictly followed when using the analyzer for your own safety.
Failure to follow these instructions may result in injuries.
The safety warning icons are used in two locations on the analyzer.
• Faceplate – Refer to Figure II-2.
• Power supply – Refer to Figure II-3.
Note: Replace the fuse only with a fuse of same rating.
Ch 1 status Ch 2 status
tCh 1
tCh 2
Figure II-2
Faceplate
Fuse Holder
Fuse
Fuse
Power Supply Fuse Type
115V 250V, 200mA Fast Acting
230V 250V, 100mA Fast Acting
170 - 264V 100mA
85 - 132V 200mA
NEUTRAL
Ground
Input Power
Figure II-3
Power Supply

Analyzer Preparation
II-6
Thermo Scientific Orion 2120XP Calcium Hardness Analyzer User Guide
Wiring the Analyzer Warning: Read and observe the following requirements. If you install the
wrong fuse for your system, you could damage the analyzer. Make sure that
you select the correct fuse rating and discard the additional fuses supplied
in the fuse kit.
• Options kit – includes fuses, cable glands, conduit fitting and green
screw terminal.
• Phillips head screwdriver.
• 2 mm blade flat-head screwdriver.
1. Open the faceplate – loosen the four screws using a Phillips head
screwdriver. The electronics faceplate will open via the hinge pin
connection.
2. Remove one or two of the two unused cable glands as required for
wiring power cable or auxiliary connections. Power cable optional hole
locations are shown in Figure II-4.
3. Select and install the appropriate size cable gland or conduit fitting
as required.
4. Feed the power cable through the conduit or cable glands as required.
Figure II-4
Electronics Enclosure
with Cable Glands
4 Captive
Screws
Hinge Pin
Power Cable
Hole Locations
Cable Glands
Electrode Cables
Required Tools