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Sievers TOC-R3
Veolia Sievers TOC-R3 User Manual
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Sievers TOC-
R3
Operation and Maintenance Manual
DLM 95000-01
EN Rev
. A
4
© V
eolia 2023
T
HIS
P
AGE
IS
I
NTENTIONALL
Y
L
EFT
B
LANK
.
3
5
Table of Contents
default chapter
3
Identification Records
3
Table of Contents
5
List of Tables
15
List of Figures
16
Confidentiality
19
Declaration of Conformity
19
Revision History
19
Standard Limited Warranty
19
Trademarks and Patents
19
English
24
Warnings
24
Chapter 1: Introduction
28
Chapter 2: System Description
30
System Specifications
30
Important
31
Applications
31
Analyzer Highlights
31
Additional System and Operating Specifications
32
Carrier Gas
32
Reagent
32
Dilution and Rinsing Water
33
Analytical Methods Supported
33
Measurement Ranges
33
Sample Information
33
Communication
34
Electrical
34
Reagent Consumption
34
Compliance
35
System Overview
35
Analyzer Enclosure Rating - IP54
35
Major Subsystems
35
Optional Subsystems and Hardware
36
Sievers TOC-R3
36
Theory of Operation
37
TOC Parameter
37
Total Nitrogen (Tnb) Parameter
38
Measurement Principle
38
Carbon Measurements
38
Included Standard Operation Analytical Methods
38
Figure 2-1: Carbon Measurement Process Diagram
38
TC Method
39
NPOC Method
39
Purchasable Analytical Methods
39
TIC Method
39
TOC Diff Method (TOC)
40
TOC Add Method
40
Purgeable/Volatile Organic Carbon (POC/VOC) Measurement
40
Tnb Measurement
40
Sample Flow Path
41
Flow Diagram
41
Figure 2-2: Flow Diagram
41
Flow Path Components
42
B1 - NDIR Detector
42
Detection)
42
B2 - ECD Detector Option (for no Detection)
43
Table 2-1: Typical NDIR Detector Measuring Ranges
43
B2 - PID Detector Option (for POC/VOC Detection)
44
Table 2-2: Typical ECD Detector Measuring Ranges
44
Sensors
45
CM1 - Injection Accumulator
45
Table 2-3: Typical PID Detector Measuring Range
45
CM2 - Multi-Function Sample Vessel
46
EB1 - Furnace
46
EC1 - Gas Cooler Unit
46
Pumps
46
Filters
47
KH1 - Pressure Regulator
47
MFSV Vent
48
RM1 - Check Valve
48
Nozzles
48
Valves
48
Table 2-4: Valves List
48
Wetted Materials
49
Table 2-5: Wetted Materials List
49
Additional System Components
51
Microprocessor Controller and Electronics
51
Data Inputs / Outputs
51
Ethernet
52
Digital Input
52
Relay
52
Analog Output
52
Options and Accessories
53
Air Box
53
Coalescing Air Filter
53
Intake Air Filter
53
Air Scrubber
53
Sievers TOC-R3
53
Soda Lime
53
Activated Carbon
54
Communication Box
54
Particulate Sampler
54
Mounting Rack
54
Chapter 3: Installation
56
Overview
56
Before Installing the Analyzer
56
Site Requirements
56
Sample Considerations
57
Power Requirements
57
Carrier Gas
57
Acid
58
Dilution and Rinsing Water
58
User Requirements
58
Step 1: Unpack and Inspect the Analyzer
59
Figure 3-1: Remove Shipping Kit and Internal Shipping Materials
60
Figure 3-2: Optional Accessory Shipping Material
60
Shipping List
61
Table 3-1: Shipping List
61
Step 2: Select a Location for the Analyzer
64
Step
64
Table 3-2: Connections/Ports List
65
Figure 3-3: Connections/Ports (View from Below)
65
Nstall any Optional I/Oor Carrier
66
Accessories
66
Communication Box
67
Install Input/Output Wiring
67
Table 3-3: Communication Box I/O Terminal Block Pin Details
68
Figure 3-4: Communication Box Terminal Block and Power Rail Connections
69
Air Box
70
Connect the Air Box Power Wires
70
Air Scrubber
70
Figure 3-5: Communication Box and Air Box Wiring
70
Prepare the Air Scrubber Housing
71
Communication Box Wire Connection
72
Connect the Communication Box to the Analyzer
72
Step
72
Onnect the Compressed
72
If Using Nitrogen
72
If Using Zero/Synthetic Air
72
If Using Plant Instrument Air (ANSI/ISA 7.0.01)
73
If Using Air Box Accessory
73
Step 5: Connect the Waste Line
74
Step
74
Onnect the Sample Line ( S )
74
Figure 3-6: Air Box Outlet Tube
74
Figure 3-7: Connect the Waste Tubing [18]
75
Connecting the Analyzer to a Sample Point
76
Installing the Particulate Sampler, Optional
76
Figure 3-8: Install the MFSV Drain Tubing in the Y9 Pinch Valve
76
Step 7: Install the Acid
77
Connect the Acid Pump Tubing
77
Prepare the Acid
78
Step 8: Install the Dilution /Rinse Water
78
Figure 3-9: Connect the Acid Pump Tubing
78
Step 9: Prepare the Furnace
79
Access the Furnace
79
Figure 3-10: Analyzer Locations - First View
79
Prepare the Furnace
80
Figure 3-11: Tilt the Furnace
80
Prepare and Install the Furnace Cartridge
81
Prepare the Furnace Head Assembly
81
Figure 3-12: Z-Brackets, Thumb Screws, and O-Ring
81
Install the Furnace Head Assembly
82
Tighten the Furnace Head Z-Brackets
82
Figure 3-13: Furnace Head Assembly
82
Insert the Injection Needle into the Injection Block
83
Figure 3-14: Tight Z-Brackets and Thumb Screws
83
Figure 3-15: Connect Injection Needle to Injection Block
83
Install the Furnace Foot Assembly
84
Figure 3-16: Ceramic Disk [16]
84
Figure 3-17: Furnace Foot Assembly [12] Groove and Correct Orientation
84
Step 10: Connecting to a Power Supply
85
Figure 3-18: Furnace Foot Assembly Z-Brackets in Groove
85
Figure 3-19: Wire Types
86
Step 11: Set the Local Analyzer Settings
88
Unlock the Analyzer
88
Set the Local Analyzer Settings
88
Figure 3-20: Gas Cooler Unit and LED (View from Above)
88
System Settings
89
To Change the Language Setting
89
Time/Date Settings
90
To Set the Current Date and System Clock
90
Figure 3-21: Select Language Dialog
90
Installing an Ethernet Connection (Optional)
91
To Install an Ethernet Cable
91
Configuring the Ethernet Connection (Optional)
91
To Configure an Ethernet Connection
91
Step 12: Perform Initial Analyzer Diagnostics
92
Check the Sensor Values
92
Table 3-4: Sensor Values
92
Adjust the "Carrier Gas Flow In" to the Analyzer
93
Exercise the Valves
93
Check the Pumps
93
Prime the Acid Pump (GP3)
93
Clear any Analyzer Errors
94
Testing any Optional Input/Output Connections
94
Figure 3-22: MFSV Acid Fill Line
94
Test the Analog Output(S)
95
Test the Relay(S) (Binary Output)
95
Sievers TOC-R3
95
Test the Digital Input(S) (Binary Input)
95
Step 13: Installation Complete
95
Chapter 4: Basic Analyzer Operation
96
Overview
96
Principles of Operation
96
Measurement Technique
96
Carbon Measurements
96
Poc/Voc
97
Tnb
97
Powering on and off the Analyzer
97
To Power on the Analyzer
97
To Shut down the Analyzer
98
Figure 4-1: Rotary Power Switch (off Position)
98
Rebooting the Analyzer
99
To Reboot the Analyzer
99
Power Cycling the Analyzer
99
To Power Cycle the Analyzer
99
Recommended Operational State
100
Figure 4-2: Rotary Power Switch
100
The Analyzer Menus and Screens
101
Navigating the Analyzer Screens
101
Touchscreen Components
102
Figure 4-3: Touchscreen Components
102
Table 4-1: Left Panel Icons
103
Table 4-2: Navigation Icons
103
To Unlock the Analyzer Touchscreen
104
Figure 4-4: PIN Dialog
104
Figure 4-5: Machine Unlocked Dialog
104
To Lock the Analyzer Touchscreen
105
Access to Functions While Locked
105
Figure 4-6: Confirm Lock Dialog
105
Data Inputs/Outputs from the Analyzer
106
Using the USB Port
106
To Take a "Screenshot
106
To "Unmount" the USB Memory Device
107
Using the Ethernet Port
107
Main Screen Selections
107
Table 4-3: Main Screens
107
Figure 4-7: Remove USB Dialog
107
Dashboard Screen
108
Figure 4-8: Dashboard Screen (Online View Example)
108
System Information Screen
109
Figure 4-9: System Information Screen
109
Acknowledging Errors
110
To Acknowledge Error(S)
110
Table 4-4: Status Icons and Actions
110
Figure 4-10: System Information Screen with Alerts (Example)
111
Figure 4-11: "Sampling" Functional Module Displaying Alerts (Example)
111
Figure 4-12: "Software" Functional Module "E1" Error Example
112
Figure 4-13: "Sampling" Functional Module "E2" Warning Example
113
Figure 4-14: "Sampling" Functional Module "E3" Maintenance Request Example
113
Maintenance Screen (Cockpit)
114
Figure 4-15: Maintenance Screen (Cockpit)
114
Gas Way
115
Soda Lime
115
Fan Filter
116
Sievers TOC-R3
116
Cartridge
116
Pump Tubing
117
Absorber
117
Menu Screen
117
Menu → Settings
118
Figure 4-16: Menu Screen
118
Measurement
119
Figure 4-17: Menu → Settings
119
Figure 4-18: Menu → Settings → Measurement
119
Signal Integration
121
Figure 4-19: Menu → Settings → Signal Integration (Defaults Displayed)
121
Methods
123
Figure 4-20: Injection Timing VS Integration
123
Figure 4-21: Menu → Settings → Methods
124
Calibration
125
Figure 4-22: Menu → Settings → Calibration
125
Limits
126
Figure 4-23: Injection Timing VS Integration
126
Figure 4-24: Menu → Settings → Limits (NPOC)
127
Figure 4-25: Menu → Settings → Limits (TC)
127
Auto Calibration
128
Figure 4-26: Menu → Settings → Auto Calibration
128
Check Function
129
Figure 4-27: Menu → Settings → Check Function
129
Rinsing
130
Figure 4-28: Menu → Settings → Rinsing
131
Menu → Service
132
Figure 4-29: Menu → Service
132
Signal
133
Result
133
Figure 4-30: Menu → Service → Signal → Signal
133
Sensors
134
Figure 4-31: Menu → Service → Signal → Result
134
Table 4-5: Sensor Details and Normal Readings
135
Figure 4-32: Menu → Service → Sensors
135
Valve Control
136
Pump Control
137
Figure 4-33: Menu → Service → Valve Control
137
Figure 4-34: Menu → Service → Pump Control
138
Analog Output
139
Figure 4-35: Menu → Service → Analog Output
139
To Set up the Analog Output(S)
140
Digital Input
141
Figure 4-36: Menu → Service → Analog Output → Test
141
To Set up the Digital Input(S)
142
Figure 4-37: Menu → Service → Digital Input
142
Relay
143
To Set up the Relay(S)
144
Figure 4-38: Menu → Service → Relay
144
Table 4-6: Digital Relay Condition Codes and Descriptions, Short List
145
Figure 4-39: Menu → Service → Relay → Relay Definition Screen
145
Furnace Control
147
To Check the Furnace Temperature While the Furnace Is off
147
Figure 4-40: Menu → Service → Furnace Control
147
Maintenance
148
Menu → Archive
148
Figure 4-41: Menu → Service → Maintenance
148
System Log
149
Figure 4-42: Menu → Archive
149
Error Log
150
Figure 4-43: Menu → Archive → System Log
150
Figure 4-44: Menu → Archive → Error Log
150
Measurement Log
151
Figure 4-45: Menu → Archive → Measurement Log
151
Measurement History
152
Figure 4-46: Menu → Archive → Measurement Log → Details
152
Calibration Log
153
Figure 4-47: Menu → Archive → Measurement History
153
Calibration Log Details Screen
154
Figure 4-48: Menu → Archive → Calibration Log
154
Figure 4-49: Menu → Archive → Calibration Log → Details
154
Menu → General
155
System Settings
156
Language
156
Figure 4-50: Menu → General
156
Figure 4-51: Menu → General → System Settings
156
Factory Settings
157
Dark Mode
157
Connectivity
157
Auto Lock
157
Auto Lock Duration
157
Sievers TOC-R3
157
Machine PIN
157
Stream 1 Name
158
Stream 2 Name
158
Info
158
Machine Configuration
158
Figure 4-52: Menu → General → Info
158
Figure 4-53: Menu → General → Machine Configuration
159
Time/Date Settings
160
Software
160
Figure 4-54: Menu → General → Time/Date Settings
160
Ethernet
161
Figure 4-55: Menu → General → Software
161
Offline Mode
162
Figure 4-56: Menu → General → Ethernet
162
Running a Calibration in Offline Mode
163
Figure 4-57: Dashboard → Offline Mode
163
Settings
164
Figure 4-58: Dashboard → Offline Mode → Calibration → Settings
164
Figure 4-59: Dashboard → Offline Mode → Calibration →Signal
165
Figure 4-60: Dashboard → Offline Mode → Calibration →Result
165
Running a Grab Sample in Offline Mode
166
Figure 4-61: Dashboard → Offline Mode → Calibration →Fit
166
Figure 4-62: Dashboard → Offline Mode → Sample → Settings
167
Figure 4-63: Dashboard → Offline Mode → Sample → Signal
167
Online Mode
168
Running in Online Mode
168
Figure 4-64: Dashboard → Offline Mode → Sample → Result
168
Figure 4-65: Dashboard → Online Mode (Example)
169
Chapter 5: Method Development
170
Overview
170
Chapter 6: Maintenance
172
Overview
172
Reagent Considerations and Preparation
173
Acid Type by Analytical Method
173
Primary Analytical Methods
173
Table 6-1: Primary Analytical Methods and Acid Type
173
Secondary Analytical Methods
174
Table 6-2: Secondary Analytical Methods and Acid Type
174
Acid Preparation
175
1% Hydrochloric Acid (Hcl)
175
1% Phosphoric Acid (H 3 PO 4 )
175
Calibration Standards
176
Stock Composition
176
Standards Preparation
176
Mg/L TC Standard
176
1,000 Mg/L TIC Standard
176
Mg/L Tnb Standard (50/50 Blend of (NH so and KNO )
177
250 Mg/L POC/VOC Standard
177
TOC Diff (TC+IC) Standard
177
Toca (NPOC + POC/VOC) Standard
177
Predictive Maintenance
178
Figure 6-1: Maintenance Screen (Cockpit)
178
Consumables
179
Table 6-3: Consumables Table and Details
179
Cleaning the Analyzer
182
To Inspect and Clean the Analyzer Exterior
183
To Inspect and Clean the Analyzer Interior
183
Cleaning the Touchscreen
183
Prepare the Analyzer for Quick Maintenance
183
Quick Maintenance Task List
184
Backing up the Analyzer Settings
184
To Backup the Analyzer Settings
184
Preparing the Analyzer for Quick Maintenance
185
To Prepare the Analyzer for Quick Maintenance
185
Quick Maintenance Procedures
185
Absorber - Aerosol Absorber (HS1)
186
Figure 6-2: HS1 - Aerosol Absorber
186
Absorber - Halogen Trap (HS2)
187
To Replace the Halogen Trap Filter Packing
187
Figure 6-3: HS2 - Halogen Trap
187
Dilution/Rinse Water
189
To Refill the Dilution/Rinse Carboy
189
Fan Filters
189
To Replace the Fan Filters
190
MFSV Vent Absorber Cartridge
190
Figure 6-4: Remove Vent Cover and Replace Filter Material (Example)
190
NDIR Disk Filter (HS3)
191
Figure 6-5: MFSV Vent Absorber Cartridge
191
Pump Head (GP4)
192
Figure 6-6: HS3 - NDIR Disk Filter Cartridge
192
Pump Tubing (GP1)
193
Figure 6-7: GP4 Pump Head
193
Reagent - Acid
194
To Refill the Acid Carboy
194
Figure 6-8: Sample Pump (GP1) Pump Tubing
194
Soda Lime and Activated Carbon (Air Scrubber)
195
To Replace the Soda Lime and Activated Carbon
195
Prepare the Analyzer for Extended Maintenance
196
Perform an Initial Analyzer Inspection
196
Errors and Sensor Readings
196
Important Sensor Values - Analyzer On, Analysis Stopped
196
Run a Single Measurement Cycle
197
Perform a Visual Inspection and Diagnostics
198
Preparing the Analyzer for Extended Maintenance
199
To Prepare the Analyzer for Extended Maintenance
199
Extended Maintenance Procedures
199
Accessing the Furnace Head Assembly
200
To Access the Furnace Head Assembly
200
Injection Needle
202
To Clean or Replace the Injection Needle
202
Figure 6-9: Furnace Head Assembly
203
Figure 6-10: Furnace Head O-Ring
203
Figure 6-11: Connect Injection Needle to Injection Block
204
Furnace Cartridge
205
To Clean or Replace the Furnace Cartridge
205
Figure 6-12: Z-Brackets, Thumb Screws, and Furnace Head O-Ring
207
Figure 6-13: Furnace Head Assembly
208
Figure 6-14: Connect Injection Needle to Injection Block
208
Accessing the Furnace Foot Assembly
209
To Access the Furnace Foot Assembly
210
To Inspect the Bottom of the Furnace Cartridge
211
Sievers TOC-R3
211
To Clean or Replace the Furnace Foot Assembly
212
Figure 6-15: Furnace Foot Assembly Correct Orientation
213
Pre-NDIR Membrane Filter (HS4)
214
Cleaning Procedures
214
Cleaning the Gas Cooler Unit Glass Tubes
214
Cleaning the Multi-Function Sample Vessel (MFSV)
215
Update the Analyzer
216
Firmware
216
To Update the Analyzer Firmware
216
Chapter 7: Troubleshooting
218
Overview
218
Step 1: Review Rrors and Warnings
218
2: Visual Inspection
218
Inspecting Externally
219
Inspecting Internally
219
Olutions for Basic Problems
220
Low Gas Flow and High Reactor Pressure
220
When Pressure Reactor Increase Is Observed
221
MFSV Not Draining
221
Gas Cooler Unit Condensate Not Draining
222
Increased Sample Recovery (NPOC)
222
Measurement Drift
222
The Analyzer will Not Power on
222
Diagnostics
222
Step 4: Contact Technical Support
223
Step
223
Eturning the
224
Nalyzer to Sievers
224
Appendix A: Dimensions and Locations
226
Overview
226
Analyzer Dimensions
226
Analyzer Dimensions - Front View
227
Figure A-1: Analyzer Dimensions, Front View
227
Analyzer Dimensions - Right Side View
228
Figure A-2: Analyzer Dimensions, Right Side View
228
Analyzer Dimensions - Left Side View
229
Figure A-3: Analyzer Dimensions, Left Side View
229
Analyzer Dimensions - View from above
230
Figure A-4: Door Swing Dimensions, View from above
230
Optional Hardware Dimensions
231
Communication Box Dimensions
232
Figure A-5: Communication Box Dimensions
232
Air Box and Air Scrubber Dimensions
233
Figure A-6: Air Box and Air Scrubber Dimensions
233
Particulate Sampler Dimensions
234
Figure A-7: Particulate Sampler Dimensions
234
Mounting Rack Dimensions
235
Figure A-8: Mounting Rack Dimensions
235
Analyzer External Connections
236
External Connections and Ports
236
Table A-1: External Connections and Ports List
236
Figure A-9: External Connections and Ports (View from Below)
236
Internal Views of Analyzer
238
Overall Internal View
239
Figure A-10: Overall Internal View
239
Figure A-11: Furnace Compartment
239
Furnace Compartment
240
Injection Block, above the Furnace
241
Figure A-12: Injection Block, above the Furnace
241
Furnace Head Assembly, Exploded
242
Figure A-13: Furnace Head Assembly, Exploded
242
Furnace Foot, below the Furnace
243
Figure A-14: Furnace Foot, below the Furnace
243
Furnace Foot, View from below
244
Figure A-15: Furnace Foot, View from below
244
Fluidics Compartment (1 of 2)
245
Figure A-16: Fluidics Compartment (1 of 2)
245
Fluidics Compartment (2 of 2)
246
Figure A-17: Fluidics Compartment (2 of 2)
246
Fluidics Compartment
246
Mfsv (Cm2)
247
Figure A-18: MFSV (CM2)
247
Figure A-19: Dilution Pump (GP4)
247
Figure A-20: Acid Pump (GP3)
247
Dilution Pump (GP4)
248
Acid Pump (GP3)
248
Gas Cooler Unit (EC1)
249
Figure A-21: Gas Cooler Unit (EC1), View from above
249
Gas Cooler Unit (EC1), View from above
249
Appendix B: Errors and Warnings
250
Overview
250
Notification Icons
250
Error Codes
251
Table B-1: Software Error Codes and Descriptions
251
Table B-2: Electronics Error Codes and Descriptions
252
Table B-3: Furnace Error Codes and Descriptions
253
Table B-4: Sampling Error Codes and Descriptions
253
Table B-5: Maintenance Request Error Codes and Descriptions
257
Analyzer Condition Codes and Descriptions
258
Table B-6: Analyzer Condition Codes and Descriptions, Full List
258
Analyzer Hardware Component Short Names
260
Table B-7: Analyzer Hardware Component Short Names
260
Appendix C: Modbus Configuration
262
Overview
262
Enabling Modbus TCP/IP Communication
263
To Enable Modbus
263
Modbus Register Data Types
264
Table C-1: Modbus Register Data Types
264
Modbus Register Map and Descriptions
265
Table C-2: Modbus Register Table
266
Appendix D: Glossary
278
Overview
278
Glossary
278
Index
284
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Veolia Sievers TOC-R3 Specifications
General
Brand
Veolia
Model
Sievers TOC-R3
Category
Measuring Instruments
Language
English
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