LAR Process Analysers QuickTOC ultra

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78 Instruction Manual QuickTOC

ultra

IECEx 12E5119

5 Start-up

5.20 Perform a Calibration LAR | PROCESS ANALYSERS AG

Main Page

Table of Contents3
Certificates11
General Information15
Safety Notes15
Safety Symbols16
Warning Sign on Casings with Explosion Protection17
Operating Principle of the Analyser19
The Sum Parameter TOC19
High Temperature Method at 1,200°C20
High Temperature Method Vs. Wet Chemical Method20
The Measurement Principle of the TOC-Difference Method20
Proceeding21
Advantages21
The Measurement Principle of the TOC-Direct Method (NPOC-Method)21
Proceeding22
Advantages22
The Measurement Principle of the Tconly Method22
2.7 Measurement and Working Ranges of the Quicktoc®Ultra24
Explosion Protection25
Product27
Scope of Delivery27
Identification Plate28
Construction of the Analyser29
Front View of the Analyser29
Right-Hand Side View of the Analyser31
Components of the Analyser31
Pump System31
Tube Cassette Pump33
Tubes (for the Tube Cassette Pump)33
Sample Pump34
Glass Components35
Ceramic Furnace37
Explosion Protection Components38
Overpressure System38
Cooling and Emergency Cooling39
Components of the Ex-Protection40
Overpressure System40
Cooling and Emergency Cooling41
Connections45
Mains Connection47
Electronic Connections (Digital and Analog Connections)48
Connections on the TRC-Board48
RS232 Serial Interface50
Digital Input50
Relays51
Analog Outputs51
Carrier Gas55
Installation57
Installation Process57
Installation of the Analyser57
Installation of Optional Accessories58
Site Selection - Ambient Conditions60
Mounting and Installation of the Analyser On-Site61
Maximum Swing Open of the Housing62
Wall Mounting63
Carrier Gas64
Sample Inlet and Drain64
Power Supply64
Signal Connections64
Rinsing Water65
Provide Acid Solution (TOC-Direct and TOC-Difference Method)65
Provide Calibration Standards66
Start-Up67
Procedure67
Start-Up of the Analyser67
Start-Up of Options67
Checking the Pre-Fusing69
Checking the Installation Plate69
Remove Transportation Locks69
Furnace Transport Screw70
Transport Lock of the XY-System71
Voltage Alignment72
Fuses Switch-On72
Reactor Pipe Filling and Installation73
Completion of the Furnace75
Installation of Glass Components77
Installation of the Pump Tubes78
Installation of the Tubes into the Tube Cassette Pump78
Installation of the Tubes into the Sample Pump78
Analyser Tubing80
Electrical Connection of the Control Unit and the Relays80
Emergency Shutdown81
Restart after Emergency Shutodown82
Connection of the Emergency Cooling for the Furnace82
Switch on the Analyser83
Setting the Bypass of the Control Unit84
Perform a Test-Run86
Rinse the Injection System und Sample Tubes86
Costumisation of Application-Specific Settings86
Checking Status Parameters86
Perform a Calibration87
Reagents and Calibration Standards89
Reagents89
Deionised Water for Calibration Standards89
Rinsing Water89
Phosphoric Acid (H3PO4) for TOC-Difference Method90
Hydrochloric Acid (Hcl) for TOC-Direct Method (NPOC-Method)90
Cleaning Solution for Glass Components91
Calibration Standards92
Calibration Standards - TOC-Difference Method92
Stock Solution - TOC-Difference Method93
Dilution of the Stock Solution - TOC-Difference Method94
Calibration Standards - TOC-Direct Method / Tconly Method95
Stock Solution - TOC-Direct Method / Tconly Method95
Dilution of the Stock Solution - TOC-Direct Method / Tconly Method96
How to Work with the Analyser97
General97
User Level97
User Interface98
Status Bar98
User Level Navigation Bar99
Control Bar99
Main View100
Keyboard100
Registration101
Operating Status101
Home Screen102
Reading Screen103
Channel Selection104
Daily Variation105
Single View106
Status Screen107
Waveform109
Measurement Settings110
Measurement Parameters111
Measurement Interval114
Measuring Channel Settings115
Channel Settings116
Relays118
Setting a Custom Relay119
Programming Tools (Logical Links)120
Testing the Relays120
Sample Stream Settings (Only User Level 3)121
Sensor Settings122
Sensors123
Threshold and Integration124
Service125
Service Parameters126
Service Actions128
Test Run130
Positioning / Adjustment of the Injection Positions (Only User Level 3)132
PC Settings133
Calibrate Analog Outputs134
Quick Test (Analog Outputs)134
Live-Zero-Feature135
Multi I/O136
Digital in137
Digital out (Only User Level 3)138
Single Measurement139
Settings140
Archive141
Single Measurement - Single View141
Calibration143
Calibration Settings145
7.10.1.1 Calibration Archive147
7.10.1.2 Calibration Archive - Calibration Points (Parameter) - Info148
7.10.1.3 Calibration Archive - Calibration Points (Parameters) - Calibration Graph148
7.10.1.4 Calibration Archive - Calibration Points (Parameters) - Waveform150
Carrying out the Calibration - Info151
Carrying out the Calibration - Graph152
Calibration Parameter Settings (User Level 3)153
Performing a Pre-Set Two-Point Calibration (User Level 2)154
Carrying out a Two-Point Calibration (User Level 3 Only)154
Performing a Multi-Point Calibration (User Level 3 Only)155
Auto-Calibration (Only User Level 3)156
Database157
Table of Measured Values158
Single View of the Measured Value (Info)159
Single View of the Channel160
Logbook161
Fault Message View162
Activity Overview163
Update Manager164
Additional Functions165
Zoom165
Export166
Status Recognition167
Status Codes167
Fault Codes168
7.15.2.1 Yellow Fault Codes168
7.15.2.2 Red Fault Codes169
Care and Maintenance171
Overview of Regular Care and Maintenance Actions172
Visual Inspections173
Performing the Visual Inspections174
Zero Signal (Weekly)174
Carrier Gas (Weekly)174
Injection System (Weekly)175
Injection Needle (Weekly)176
Glass Components (Weekly)176
Canister and Supply Tubes (Weekly)176
Inlet and Drain Tubes (Weekly)176
Injection Tube (3 Months)177
TIC-Stripping Vessel (3 Months)178
Running Rails (XY-System) (3 Months)179
Tube Cassette Pump and Pump Tubes (3 Months)179
Sample Pump and Pump Tubes (3 Months)179
Viton Tubes (3 Months)179
Acid Trap (3 Months)179
Quartz Wool Filter (3 Months)180
Care Actions181
Perform Care Actions182
Rinse the Injection System182
Clean Glass Components182
Fill Canisters182
Clean Canisters183
Clean Supply Tubes183
Clean Inlet and Drain Tubes183
Clean Teflon Tube (Reactor Foot)183
Clean the Reactor Foot184
Clean Injection Tube184
Cleaning the Reactor Pipe185
Clean TIC Stripping Vessel186
Clean Gas Cooling Pipe186
Clean Running Rails (XY-System)186
Grease Running Rails (XY-System)187
Cleantube Cassette Pump and Pump Cassettes187
Clean Sample Pump188
Adjust Sample Pump188
Clean Viton Tube189
Clean Injection Needle189
Renew Calibration Standard189
Clean Needle Guide (Injection Port)189
Furnace System Check190
Check the Gas Cooling Pipes191
Clean and Oil Injection Port192
Move Pump Tubes (Tube Cassette Pump)193
Check the Mechanical Backlash of the XY-System193
Check the Injection Port194
Maintenance Actions195
Perform Maintenance Actions196
Replace Supply Tubes196
Replace Inlet and Drain Tubes196
Replace Teflon Tube (Reactor Foot)196
Replace Reactor Pipe Filling / Reactor Pipe197
Replace Small Furnace Head Seal199
Replace Big Furnace Head Seal (Silicone O-Ring with PFA Coat)200
Replace Injection Tube200
Replace Viton Tube200
Replace Acid Trap Filling201
Replace Acid Trap201
Replace Quartz Wool Filter Filling202
Replace Quartz Wool Filter202
Replace Injection Needle203
Replace Silicone Seal for TIC-Port (TOC-Difference Method)203
Replace Needle Guide Seal (Injection Port)204
Replace Silicone Seals for Glass Components204
Replace Reactor Foot Seal205
Replace Pump Tube (Tube Cassette Pump)206
Replace Pump Tube (Sample Pump)207
Replace Gas Filter207
8.8 Function Tests208
Check Analyser Status209
Tightness Test210
Test Run (XY-System)210
Checking the Measurement Results210
Checking the Measurement Process210
Short-Time- and Long-Time Interruptions211
Switching On/Off for Short-Time-Interruptions (<1 Week)211
Switching On/Off for Long-Time Interruptions (>1 Week)211
Accessories and Options216
Overview216
Reagent Cabinet217
Construction of the Reagent Cabinet217
Installation of the Reagent Cabinet218
Start-Up of the Reagent Cabinet219
Activated Carbon219
Soda Lime Pellets with Indicator220
The Carrier Gas for the Measurements Must Meet Certain Criteria (). Ambient Air Must be Conditioned Accordingly if Used. the Tubing for the Ambient Air Preparation Unit Is Shown below221
Use the Holes Q1 and Q2 of the Mounting Rack and the Air Preparation Brackets221
This Prevents Consumption of Soda Lime Cookies with Indicator221
Maintenance222
Perform Visual Inspection223
Once All Test Criteria Are Met, Proceed with the Next Stepsoda Lime223
Tube Connections223
Pre Pressure of the Carrier Gas223
Perform Care and Maintenance Actions (Ambient Air Preparation Unit)224
Replace Soda Lime224
Replace Gas Filter225
Replace Filter Mats227
Replace Fine Filter Unit227
Replace Coarse Filter Unit228
Replace Activated Carbon228
9.3 Proceed Analogously to the Replacement of the Soda Lime in Chapter 9.2.7.1 From Page 213Flowsampler231
Flowsampler® DN25231
Flowsampler® DN17231
Installation of the Flowsampler232
Start-Up of the Flowsampler232
Care and Maintenance Actions (Flowsampler®)233
Perform Visual Inspections (Flowsampler®)234
Flow234
Sampling Pipe (Needle)234
Perform Care and Maintenance Actions (Flowsampler®)235
Clean Sampling Pipe (Needle)235
Clean Flowsampler235
Overflow Sampler236
Construction of the Overflow Sampler236
Connections236
Set-Up237
Care and Maintenance (Overflow Sampler)238
Perform Visual Inspection (Overflow Sampler)239
Flow239
Perform Care and Maintenance (Overflow Sampler)239
Clean Overflow Sampler240
CO2-Remover241
Start-Up of the CO2-Remover243
Care and Maintenance Actions (CO2-Remover)244
Perform Visual Inspections (CO2-Remover)245
Housing245
Service Lamp245
Mounting Rack246
Trackball248
Multi Stream Option249
Multi Parameter Option250
High Salt Option251
Auto-TIC-Port252
Construction of the TIC Reactor with Auto-TIC-Port252
Start-Up of the TIC Reactor with Auto-TIC-Port252
Care and Maintenance Actions (Auto-TIC-Port)253
Perform Visual Inspections (Auto-TIC-Port)254
Microswitch on Auto-TIC-Port (6 Months)254
Perform Care and Maintenance Actions (Auto-TIC-Port)255
Replace Needle Guide Seal (Auto-TIC-Port) (1 Month)255
Clean Needle Guide (Auto-TIC-Port) (1 Month)256
Clean and Oil Auto-TIC-Port (3 Months)257
Internal Sample Dilution258
Software Settings for the Internal Sample Dilution258
Flow Diagram with Internal Sample Dilution259
Minor Disruptions - Quickly Solved260
Preconditions for Fault-Free Measurement Mode260
Breakdowns261
Check the Fuses - Automatic Circuit Breaker262
Breakdowns of the Temperature Regulators263
Technical Information264
Device Specifications264
Ambient Conditions265
Specifications for Accessories and Options265
Flow Diagrams266
Component Labelling266
TOC-Difference Method (1 Sample Stream)268
TOC-Difference Method (3 Sample Streams)269
TOC- Direct Method (1 Sample Stream)270
TOC-Direct Method (2 Sample Streams)271
Tconly-Method (1 Sample Stream)272
Tconly-Method (2 Sample Streams)273
Flow Diagram with Internal Sample Diluition (Option)274
Operating, Care and Maintenance Logs276
Operating Log277
Visual Inspections Log (Analyser)278
Care Log (Analyser)279
Maintenance Log (Analyser)280
Function Test Log (Analyser)281
Visual Inspection Log (Ambient Air Preparation Unit)282
Care and Maintenance Log (Ambient Air Preparation Unit)283
Visual Inspection Log (Flowsampler)284
Care and Maintenance Log (Flowsampler)285
Care and Maintenance Log (Overflow Sampler)286
Visual Inspection Log (CO2-Remover)287
Care and Maintenance Log (CO2-Remover)288
Visual Inspection Log (Auto-TIC-Port)289
Care and Maintenance Log (Auto-TIC-Port)290
Safety Data Sheets292
Contact294
Contact to LAR294
Distributors / Authorized Service Partners294
Optimization294

LAR Process Analysers QuickTOC ultra - Page 88

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