Operating Instructions

EZ-TOC II analyzer CA52TOC
Analyzer for continuous real-time TOC measurement in water
and wastewater

BA424C/07/en/06.09
71085882

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EZ-TOC II analyzer CA52TOC

Table of contents
1

Safety instructions . . . . . . . . . . . . . . . . 4

7Maintenance . . . . . . . . . . . . . . . . . . . . 43

1.1
1.2
1.3
1.4
1.5

Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation, commissioning and operation . . . . . . . . 4
Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Notes on safety icons and symbols . . . . . . . . . . . . . . 5

7.1
7.2

2

Identification . . . . . . . . . . . . . . . . . . . . 6

2.1
2.2
2.3

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.1 Product structure . . . . . . . . . . . . . . . . . . . . 6
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Certificates and approvals . . . . . . . . . . . . . . . . . . . . 7

3Installation . . . . . . . . . . . . . . . . . . . . . . 8

Biweekly maintenance . . . . . . . . . . . . . . . . . . . . . . 45
Monthly maintenance . . . . . . . . . . . . . . . . . . . . . . 45
7.2.1 Replenish reagents . . . . . . . . . . . . . . . . . . . 45
7.2.2 Reset reagent timer . . . . . . . . . . . . . . . . . . 45
7.2.3 Inspect entire unit . . . . . . . . . . . . . . . . . . . 45
Quarterly maintenance . . . . . . . . . . . . . . . . . . . . . 47
7.3.1 Replacement of pump tubing . . . . . . . . . . . 47
7.3.2 Internal cleaning of analyzer . . . . . . . . . . . 48
7.3.3 Leak-testing of gas lines . . . . . . . . . . . . . . . 49
7.3.4 Manual liquid calibration . . . . . . . . . . . . . . 49
7.3.5 Automatic clean . . . . . . . . . . . . . . . . . . . . . 50
7.3.6 Automatic calibration . . . . . . . . . . . . . . . . . 51
7.3.7 Alarm Standards . . . . . . . . . . . . . . . . . . . . 51

3.1
3.2

3.4

Incoming acceptance, transport, storage . . . . . . . . . . 8
Installation conditions . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.2 Compressed air supply . . . . . . . . . . . . . . . . . 9
Installation instructions . . . . . . . . . . . . . . . . . . . . . 10
3.3.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.2 Installing the UV lamp . . . . . . . . . . . . . . . . 10
3.3.3 Connecting the gas sources . . . . . . . . . . . . 11
3.3.4 Connecting the medium . . . . . . . . . . . . . . 12
3.3.5 Preparing chemicals . . . . . . . . . . . . . . . . . . 13
Post-installation check . . . . . . . . . . . . . . . . . . . . . . 17

4

Wiring . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1

4.2

Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.1 Preparing wiring . . . . . . . . . . . . . . . . . . . . 18
4.1.2 Electrical connection of analyzer . . . . . . . . 19
4.1.3 Connecting the signal outputs . . . . . . . . . . 20
4.1.4 Connecting the relay outputs . . . . . . . . . . . 21
Post-connection check . . . . . . . . . . . . . . . . . . . . . . 21

5

Operation . . . . . . . . . . . . . . . . . . . . . . 22

5.1
5.2

Operating elements . . . . . . . . . . . . . . . . . . . . . . . . 22
Display and keypad . . . . . . . . . . . . . . . . . . . . . . . . 23

6

Commissioning. . . . . . . . . . . . . . . . . . 24

6.1
6.2

Function check . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.1 COMMANDS menu . . . . . . . . . . . . . . . . . 24
6.2.2 CALIBRATION menu . . . . . . . . . . . . . . . . 26
6.2.3 SETUP menu . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.4 DIAGNOSTICS menu . . . . . . . . . . . . . . . . 39
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.3

3.3

8

Accessories . . . . . . . . . . . . . . . . . . . . . 52

9Troubleshooting . . . . . . . . . . . . . . . . . 53

9.1
9.2
9.3
9.4
9.5

Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10Technical Data. . . . . . . . . . . . . . . . . . . 59

10.1
10.2
10.3
10.4
10.5
10.6
10.7

Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Performance characteristics . . . . . . . . . . . . . . . . . . 60
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Mechanical construction . . . . . . . . . . . . . . . . . . . . 60

Index . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.3

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3

Safety instructions

EZ-TOC II analyzer CA52TOC

1

Safety instructions

1.1

Designated use

CA52TOC is an analyzer for continuous real-time TOC measurement in water and wastewater.
The analyzer is particularly suitable for use in the following areas:• Monitoring of organic carbon in water and wastewater• Industrial processes• Outlet monitoring in sewage treatment plants• Monitoring of spring water and drinking water• Control of methanol dosage
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 thatelectrical 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 perfectfunctioning 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.
Immunity to interferenceThis instrument has been tested for electromagnetic compatibility in industrial use according toapplicable European standards.
Protection against interference as specified above is valid only for an instrument
connected according to the instructions in these Operating Instructions.

4

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EZ-TOC II analyzer CA52TOC

Safety instructions

1.4

ReturnIf 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#

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.
Electrical symbols

%
&

)
*
b

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.
Alarm relay

Input
OutputDC voltage source
Temperature sensor

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5Identification

EZ-TOC II analyzer CA52TOC

2

Identification

2.1

Nameplate

Please check the order code from the nameplate with the product structure and with your order.
Anaheim, CA 92807 USA

EZ-TOC II
Order Code:

IP54

Meas. range:
0.015 to 100 mg/l TOC

CA52TOC- 1012/0
CA52TOC-A1B0A0A
Serial No.:

C1000A517W0

Mains: 230 V, 50/60 Hz

300 VA

Output:
0/4 to 20 mA
Ambient temp.: >0 to 40 °C>32 to 104 °F
Contacts:

4 relaysa0010818

Fig. 1:

2.1.1

Nameplate (example)

Product structure
Measuring range
A
B
C
D
E
F
Y

0.015 to 10 mg/l TOC
0.1 to 100 mg/l TOC (not with CA52TOC-**C****)
0.5 to 500 mg/l TOC (not with CA52TOC-**C****)
10 to 1000 mg/l TOC (not with CA52TOC-**C****)
50 to 5000 mg/l TOC (not with CA52TOC-**C****)
100 to 10000 mg/l TOC (not with CA52TOC-**C****)
Special version according to customer specification

Sample transfer
1
2

1 measuring point (not with CA52TOC-****D**; CA52TOC-****E**)
2 measuring points

TIC removal
A
B
C
Y

Standard
High
Ultra high (only with CA52TOC-A******)
Special version according to customer specification

Power supply
0
1

230 VAC, 50/60 Hz
115 VAC, 50/60 Hz

Sample preparation
A
B
C
D
E
Y

Not selected
1 x PA-2 PVC, 1 to 8 m3/h (4.4 to 35 gpm) wastewater
1 x PA-3 PVC, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater
2 x PA-2 PVC, 1 to 8 m3/h (4.4 to 35 gpm) wastewater (not with
CA52TOC-*1*****)
2 x PA-3 PVC, 0.1 to 1.0 m3/h (0.4 to 4.4 gpm) wastewater (not with
CA52TOC-*1*****)
Special version according to customer specification

Carrier gas
0
1
2
9

To order separately
CO2 scrubber
CO2 scrubber + compressor
Special version according to customer specification

OutputA
CA52TOC-

6

0/4 to 20 mA + RS 232 unidirectional
Complete order code

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EZ-TOC II analyzer CA52TOC

Identification

2.2

Scope of delivery

The scope of delivery comprises:• 1 EZ-TOC II analyzer CA52TOC• 1 set of tubing (4 pieces)• 1 set of fittings (17 pieces)• 2 bottles (5.5 US gal)
• 3 bottles (2 US gal)
• 5 bottle caps (with hole for tube)• Operating Instructions, English• 1 Allen key• 1 drain plug with gasket• 1 special key for peristaltic pump
• 1 key for door lockIf 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 withthe legal requirements of the EC directives.
The manufacturer confirms successful testing of the product by affixing the 4 symbol.

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7

Installation

EZ-TOC II analyzer CA52TOC

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 matterhas 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 theapproved ambient conditions (see "Technical data").
• If you have any questions, please contact your supplier or your local sales center.

3.2

Installation conditions

3.2.1

Location

The analyzer can be installed in two ways:• standalone on a table• mounted on a wall
The analyzer requires a gravity drain which is vented to the atmosphere.
If located inside a building, a vent is required. The accumulation of halogens or other vapors is not
permitted in this area.
558.9 (22.00)
529.7 (20.85)
508 (20.00)

841.9 (33.14)
802 (31.57)
762 (30.00)

663 (26.10)
610 (24.00)
572 (22.50)

365.4 (14.39)
369.2 (14.54)

Æ 9.53 (.375)
305 (12.00)

mm (inch)a0008101

Fig. 2:8

Dimensions

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EZ-TOC II analyzer CA52TOC

Installation

3.2.2

Compressed air supply

The compressed air (used as a carrier gas) must be dry and must meet the following specifications:• < 3 ppm CO2• < 3 ppm hydrocarbon• Constant pressure 2 bar (29 psi).
• Consumption 500 to 750 cm3/min• The in-house compressed air supply must be equipped with a CO2 scrubber (input pressure 4.0
to 10 bar (58 to 145 psi)) and a pressure reducing valve.
Bottled air, nitrogen or oxygen can also be used as a carrier gas.

1

2

3

4

5

a0008041

Fig. 3:1
2
3
4
5

Measuring system when air supply is unstable
EZ-TOC II analyzer CA52TOC
Pressure regulator
CO2 scrubber
Pressure regulator
Air reservoir > 5 l (> 1.3 US gal)

1

2

3

4

a0008042

Fig. 4:1
2
3
4

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Measuring system when air supply is stable
EZ-TOC II analyzer CA52TOC
Pressure regulator
CO2 scrubber
Stable air supply (or bottle) > 6 bar (> 87 psi)

9

Installation

EZ-TOC II analyzer CA52TOC

3.3

Installation instructions

3.3.1

Mounting

The analyzer has four mounting holes in the back of the cabinet. Use at least 10 mm (5/16")
mounting hardware to support the unit, as it is heavy. The mounting feet on the back of the analyzer
provide clearance between the wall and the cabinet.

3.3.2

Installing the UV lamp

" Caution!
The UV lamp is extremely fragile. Perform installation with care.
12a0011122

Fig. 5:

UV reactor

Preparation

10

1.

Open the cabinet door and swing out the analyzer’s front panel. Block the door and panel, sothat they will not swing back.

2.

Remove the top Phillips screw on the reactor ground strap (pos. 1, Fig. 5).

3.

Remove the Phillips screw above the ground strap (pos. 2, Fig. 5).

4.

Remove the reactor cap.

5.

Remove the top of the reactor shell.

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EZ-TOC II analyzer CA52TOC

Installation

Installing the lamp
1.

Inside the reactor, remove the reactor nut and the two O-rings beneath it.

2.

Carefully slide first the reactor nut, then the two O-rings, over the glass end of the UV lamp to
the top of the lamp.

3.

Insert the lamp into the center of the reactor. Exert a gentle downward pressure on the lamp
as you tighten the reactor nut. The lamp’s metal sleeve must be against the nut.

4.

" Caution!
Tighten with care.
Undertightening the reactor nut can result in leakage, causing damage to the analyzer.
Overtightening the reactor nut can break the outer casing of the UV lamp.
Hand-tighten the reactor nut, and then tighten it by one additional half turn.

5.

Replace the top, cap and ground strap on the reactor shell.

3.3.3

Connecting the gas sources

Gas and liquid connections are all made via the connection panel located in the lower right-handside of the cabinet.

IR Vent

Calibration

Deionized
Water

Clean
Solution
Air In30 psiMax. Pressure
2 BarsDilution

ManualSampleSodiumPersulfate

Acid
Vent

Sample In

Sample Out

Drain

Purge

a0010722

Fig. 6:

Connection panel for gas and liquid connections

All connections are made using PFA or Kynar® fittings. Tighten the fittings securely, but be careful
to avoid overtightening the fittings, as you may destroy the threads.

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11

Installation

EZ-TOC II analyzer CA52TOC

3.3.4

Connecting the medium

Connecting the air supply:
1.

Use PFA tubing to attach the air supply line to the "Air In" fitting.

2.

Tighten the fittings securely.

" Caution!
Do not under any circumstances allow the air pressure entering the analyzer to exceed 2 bar (30 psi)
maximum, as this could damage the analyzer and result in personal injury.
3.

Turn on the air supply.

4.

Use a mixture of water and soap to check for leaks. Paint the mixture directly onto theconnections at the analyzer and the air supply. If there is a leak, bubbles will form around theconnection. Tighten the fitting a little more and recheck the connection. Do not overtighten
the fittings or you may destroy the threads.

Connection of the liquid medium:12

1.

Place the medium bottles close to the analyzer.

2.

Pour the reagents (acid, persulfate) into the two 5.5 US gal bottles. Pour the cleaning,calibration and DI solutions into the three 2 US gal bottles. Use the bottle caps with a hole(included in the delivery) during operation of the analyzer. Use the bottle caps without a holefor transport and storage.

3.

Cut five pieces of 1/8" PFA tubing long enough to reach the bottom of the medium bottles andthe medium connections of the connection panel.

4.

Pass the ends of the tubes through the holes in the bottle caps to the bottom of the bottles.

5.

Connect the other ends of the tubes to the corresponding fittings on the connection panel.

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EZ-TOC II analyzer CA52TOC

Installation

3.3.5

Preparing 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".
Precautions regarding use of chemicals• Read the material safety data sheets (MSDS) provided with each chemical to see what hazards arepresent and what precautions you must take. If you are not sure of the risks, seek assistance from
qualified individuals.
• Never prepare chemicals by yourself. If an accident happens, you may need help. Make suresomeone else is nearby. Prepare chemicals only in a properly-equipped lab facility.
• Always wear goggles, rubber gloves and a rubber apron when preparing chemicals. If you workwith finely powdered chemicals, wear a protective face mask or respirator.
• Never breathe, taste, or swallow any chemical or solution used with the EZ-TOC II analyzer (orany other process analytical device).
• When solutions are prepared, always label containers with contents and date of preparation.
Dispose of unlabeled or expired solutions in accordance with local regulations.
• Some chemicals react violently when combined or dissolved in water, causing explosions, fire,
heat, or the dangerous discharge of gases, foam or spray. Avoid the risk of a serious accident; if
you do not know how certain chemicals will react, do not combine them. Never combine
chemicals known to react very strongly.
There are three chemical solutions normally used with the EZ-TOC II. They are:• Phosphoric acid, H3PO4, 10% (v/v) solution
It is used to acidify the sample solution. This transforms carbonate ion (CO3=) to CO2 andeliminates dissolved CO2 from the solution.
• Potassium Hydrogen Phthalate (KHP) 1–10,000 mg/l
This is the standard solution used to calibrate the analyzer. Other chemicals can be used.
• Sodium Persulfate, Na2S2O8, 1.5 M(Note that this chemical is also called sodium peroxidisulfate.) It is used with UV light in theanalyzer to oxidize the organic carbon in the sample.
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, and10,000 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, andas 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 theanalyzer. Inaccurate preparation of the standard will result in an erroneous calibration, which inturn 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 andexposure to air can ruin sensitive solutions quickly.

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13Installation

EZ-TOC II analyzer CA52TOC

Preparation of phosphoric acid

" Caution!
Phosphoric acid can cause blindness and burns to the skin. Always add acids to water; never thereverse. Wear goggles, gloves, and a rubber apron.
Shelf life: Indefinite, 10% (v/v) solution.
Procedure:For 2 l (0.53 US gal)Mix 200 ml (6.75 fl.oz) of concentrated phosphoric acid (85%) with
1,800 ml (0.48 US gal) of deionized (DI) water. This will yield 2 l of 10%(v/v) acid.
For 1 l (0.264 US gal) Mix 100 ml (3.38 fl.oz) of concentrated phosphoric acid (85%) with
900 ml 0.237 US gal) of deionized water.
For 20 l (5.5 US gal) Mix 2 l (0.53 US gal) of concentrated phosphoric acid (85%) with 18 l
(4.75 US gal) of deionized water.
Preparation of sodium persulfate" Caution!
Sodium persulfate is a strong oxidizing agent. It can cause burns to your skin and damage to therespiratory system. It can also start fires when mixed with combustible materials. Do not breathe
the dust or ingest the prepared solution. This solution is very strong (1.5 M); do not spill it on yourskin or clothing. It may bleach out colors or attack certain fabrics.

! Note!
This reagent needs to age; prepare it 24 hours before you need to use it. Label the container with
the name of the contents and the date of preparation.
Shelf life: 4 to 6 weeks; 1.5 molar
Procedure:For 2 l (0.53 US gal)

Add deionized water to 700 g (24.6 oz) of sodium persulfate to a total of
2 liters and mix.
For 1 l (0.264 US gal) Add deionized water to 350 g (12.3 oz) of sodium persulfate to a total of
1 liter and mix.
For 20 l (5.5 US gal) Mix 7 kg (15.4 lbs) to 10 l (2.64 US gal) of deionized water to dissolve thepersulfate, then add enough water to make 20 l (5.28 US gal) of solution.
Note that when you mix this solution there will be an endothermic reaction (the bottle will becomecold). At 25° C (77° F), the maximum solubility of sodium persulfate in water is 425 g (15 oz) per l.
As temperature decreases, so does solubility. 700 g (24.6 oz) in 2 l (0.53 US gal) of water will takethe same time to dissolve and at this concentration should not recrystallize inside the unit.
Preparation of potassium hydrogen phthalate" Caution!
Potassium Hydrogen Phthalate (KHP) can cause eye and skin irritation, and respiratory problems.
Do not breathe the dust or ingest the prepared solution.
Shelf life: Relatively stable, depending on concentration. (Stability decreases with decreasing
concentration; refrigeration is suggested.)
Concentrations: Application-dependent.

14

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EZ-TOC II analyzer CA52TOC

Installation

Procedure:
For a 10,000 mg/l organic carbon solution, dissolve 21.254 grams of reagent grade (or better) KHP
in 500-700 ml of deionized water in a one-liter volumetric flask (refer to the following table forother concentrations of solution). After the chemical is dissolved, add water to bring the total
volume to one liter. Remix the solution. Label the container with the name of the contents and thedate of preparation.
mg/l Carbon

g KHP

Volume10,00021.2541l

1,000

2.12541l

500

1.06271l

1000.212541l

100.021254

1l

The 10,000 mg/l solution is stable (especially if refrigerated). It is suggested that serial dilutions
be made from a 10,000 mg/l standard to lower concentrations as needed. For example:• 10 ml of 10,000 mg/l solution diluted with 90 ml deionized water yields a 1,000 mg/l solution.
• 10 ml of 1,000 mg/l solution diluted with 90 ml deionized water yields a 100 mg/l solution.
• 10 ml of 100 mg/l solution diluted with 90 ml deionized water yields a 10 mg/l solution.
The serial dilution is preferred for making the lower concentrations rather than taking 1 ml fromthe 10,000 mg/l solution and diluting it with 99 ml of deionized water. Using this latter method
could introduce an error in measurement.
Note that while stock standards of 1,000 and 10,000 mg/l are fairly stable at room temperature forseveral weeks, 10 mg/l solutions will begin to degrade at room temperature within 3 to 5 days.
Note also that you should keep the container of the crystalline KHP closed. Left open to theatmosphere, it will readily absorb water and have to be dried prior to use. Otherwise, yourmeasurements will be inaccurate, due to the lower concentrations of carbon in the hydrated salt.
Dry exposed KHP at 105 °C (221 °F) for one hour.
Use of other acids
Generally phosphoric acid is the acid recommended for use in the analyzer. The reasons for this are
as follows:• It is a strong enough acid that very little is needed to reduce the stream pH to 2.0.
• It usually has very little organic content of its own.
Phosphoric acid is not recommended if the sample stream contains high concentrations of Group II(alkaline earth) metal ions, specifically calcium (Ca++) or magnesium (Mg++) or both. These ions will
form insoluble phosphates. These precipitates could plug the TIC scrubber and the U-tube drain.
Enough deposits can ruin the glassware. Use a different inorganic acid such as 5% Nitric (HNO3).

" Caution!
Nitric acid is a poison and a strongly corrosive acid capable of causing serious skin burns andblindness. Reactions with metals or other chemicals can release toxic, irritating fumes (oxides ofnitrogen). Nitric acid is a strong oxidizing agent that can produce dangerously unstable byproducts.
Note that nitric acid is used in the production of many explosives.
If you must use other acids, prepare the dilutions with care:• Always follow good laboratory procedures.
• Use a vented hood to exhaust any fumes that could evolve from the preparation.
• Always add acid to water.
• Avoid any spillage or skin contact and never work with the concentrated acids by yourself.

Endress+Hauser

15

Installation

EZ-TOC II analyzer CA52TOC

Use of other chemicals for TIC standards
For TIC (Total Inorganic Carbon), the most commonly used standard is sodium carbonate,
Na2CO3.
Prepare solutions as follows:• 1,000 mg/l
Add 8.833 g of Na2CO3 to a 1 l volumetric flask, then fill with deionized water.
• 10,000 mg/l
Add 88.33 g of Na2CO3 to a 1 l volumetric flask, then fill with deionized water.
Serial dilutions can be made as described previously for the KHP standard.
You can also use potassium carbonate, K2CO3 for the TIC standard.
Prepare solutions as follows:• 1,000 mg/l
Add 11.517 g of K2CO3 to a 1 l volumetric flask, then fill with deionized water.
• 10,000 mg/l
Add 115.17 g of K2CO3to a 1 l volumetric flask, then fill with deionized water.
Both Na2CO3 and K2CO3 standards are stable at room temperature for up to two weeks if thedeionized water is above pH 7. Keep the containers closed to delay the eventual transformation of
the carbonate into bicarbonate salt.
Use of other chemicals for TOC standards
Other carbon-containing chemicals have been used for TOC standards for various reasons. For the
purpose of consistency, these compounds must be nonvolatile and have carbon that can be madeto react effectively enough in the analyzer. Some examples are ethylene glycol, benzoic acid andsucrose.
The amounts given below are to prepare one liter of 1,000 mg/l solution. Other solutions can bemade by using the serial dilution method described previously for KHP or by increasing the quantity
tenfold to make a 10,000 mg/l concentration.
Ethylene Glycol - (C2H4(OH)2) This is readily available from supply houses and oxidizes easily inthe analyzer. It is easy to handle and is infinitely soluble in water. However, you must keep thecontainer tightly closed, as the substance rapidly absorbs water when exposed to air, and displays
no obvious physical change when it has been diluted.
To make a 1,000 mg/l solution, add 2.586 grams to a 1 liter volumetric flask, then fill with
deionized water.
Benzoic Acid - (C6H5CO2H) To make a 1,000 mg/l solution, add 1.454 grams to a 1 liter
volumetric flask, then fill with deionized water. This agent is chemically similar to phthalic acid,from which KHP is made.
Sucrose - (C12H22O11) Sucrose is not usually recommended, but is sometimes used when otherstandards are not readily available. Common table sugar can be used as a fair approximation in an
emergency. For a 1,000 mg/l solution, add 2.377 grams to a 1 liter volumetric flask, then fill with
deionized water.
Chemicals not recommended for standards
The following chemicals are not recommended for use as standards in the analyzer. They are notsuitable for various reasons. They may not be soluble in water, or their boiling point may be too low.
If the boiling point is too low, the solution will separate in the reactor and you will be unable toestablish an accurate standard.
Methanol - (CH3OH) Also called methyl alcohol or wood alcohol. Boiling point is 65 °C (149 °F).
Ethanol - (C2H5OH) Also called ethyl alcohol or grain alcohol. Boiling point is 78 °C (172 °F).
Acetone - (CH3COCH3) Also called dimethyl ketone, 2-Propanone. Boiling point is 56 °C (133 °F).
MEK - (CH3CH2COCH2) Also called methyl ethyl ketone, 2-Butanone. Boiling point is 80 °C(176 °F).
Carbon Tetrachloride - (CCl4) Boiling point is 76 °C (169 °F), CCl4 is toxic, and is essentiallyinsoluble in water.
Compounds that oxidize with difficulty in the UV-persulfate process, should be avoided. An
example of this would be oxalic acid (H2C2O4) or urea (NH2CONH2).
16

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EZ-TOC II analyzer CA52TOC

Installation

Cleaning solutions
Cleaning solutions for the analyzer are usually dependent on the particular site application for theireffectiveness. Consequently, only general recommendations can be made about the composition of
the cleaning agents.

# Warning!
Cleaning solutions for laboratory equipment usually contain strong acids and/or strong oxidizing
agents. They are highly toxic and very corrosive, and can cause severe skin burns. Prepare and use
them with care. Never spill them on skin or clothing.
As a starting point, we recommend a solution that is composed of a combination of the two reagentsused to oxidize the carbon. This solution is 50% of the used acid (10% solution) and 50% sodium
persulfate solution (1.5 M) by volume.
This solution will normally remove accumulations of organic and inorganic carbon from theanalyzer. However, plating, foaming, precipitation, or solidification problems are site-dependent,
and must be handled on a site-by-site basis.
Site operators are urged to monitor their installations closely in the first days and weeks of operation
for signs of precipitation, clouding, coating, or staining on the glassware that could indicate
problems. The important thing is to catch problems early. If you observe rapid clouding or
discoloration of the glassware and cannot dissolve it, contact your Endress+Hauser representative
immediately. In such cases, it is frequently necessary for site operators to experiment with various
chemical agents to identify the best possible combination. Detailed chemical analysis of the stream
may be necessary to determine the cause of the problem. The Endress+Hauser Service Department
may be able to provide assistance to you in the selection of more suitable cleaning agents forconditions at your site. However, there may be situations where it will be difficult or impossible toidentify a cleaning agent that will perform satisfactorily.

! Note!
Have your sample water or waste stream analyzed for chemical content and concentration before
you install the analyzer so you will know what is in the waste stream.
Waste streams can contain a great number of different chemicals in highly variable levels ofconcentration. It would be impossible to predict all the possible chemical interactions that could
occur inside a TOC analyzer. Endress+Hauser cannot be responsible for damage to the analyzer
caused, in Endress+Hauser’s opinion, by reactions of chemicals present in the stream or improper
maintenance.

3.4

Post-installation check• After installation, check that all connections are tightly fitted and are leak-resistant.
• Check all hoses for damage.

Endress+Hauser

17

Wiring

EZ-TOC II analyzer CA52TOC

4

Wiring

4.1

Electrical connection# Warning!
• 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.
• Ensure that there is no voltage at the power cable before beginning the connection work.

4.1.1

Preparing wiring# Warning!
• Ensure before connection that the mains voltage corresponds with the voltage specified on the
nameplate.
• The unit must have its own dedicated, unswitched circuit.

! Note!
To ensure that the cabinet remains resistant to dust and water, use appropriate conduits and fittings
for all electrical connections.

2

3

1

a0010688

Fig. 7:1
2
3

Inside back of cabinet
Terminal box
Non-dispersive infrared detector (NDIR)
Power supply

The following connections must be made:• AC power connection• 4-20 mA analog output loop
• RS-232 serial loop (computer) connection• Relay board connections

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EZ-TOC II analyzer CA52TOC

WiringIf you install the analyzer using conduit, use either rigid conduit or a flexible, liquid-tight conduit.
Use the correct fittings with either type of conduit to maintain the resistance of the unit to liquid
infiltration.
If you do not use conduit when installing the analyzer, use cord-grip fittings. These fittings use anelastomeric gland (bushing) around the cable which compresses around the cable while a nut istightened on the fitting, to form a tight seal. However, please note that cord-grip fittings are specificto wire size. You must have the correct size for the cables you are using in the installation. You
should also use sealing washers between the cord-grip fittings and the cabinet wall. Cord grip
fittings are available from Endress+Hauser.

4.1.2

Electrical connection of analyzer

12 11 10 9 8 7 6 5 4 3 2 1

C
NO NC
Rel 4

+
Data
Common

Rel 3

Rel 2

C
NO NC
Rel 1

1
2
3
4

4 - 20 mA
Serial data

115/230 V AC
L
N
PE
a0010686

Fig. 8:Terminals

AC power
Power wire specification:• Cross section at least 14 AWG or 1.0 mm2• Insulation rated for 60 °C (140 °F) or better
Connect the AC power cable according to Fig. 8. Place a tie wrap around them to hold them inposition.

! Note!
Note the small handles facing you on the left side of the terminal block. These handles are the levers
for fuses. If you pull outwards on the handles, an insert that houses a fuse will pop out of theterminal block.

Endress+Hauser

Power

Fuses

230 V AC2 x microfuse 1.25 A, 250 V, slow-blow

115 V AC

1 x microfuse 3.0 A, 250 V, slow-blow

19

Wiring

EZ-TOC II analyzer CA52TOC

4.1.3

Connecting the signal outputs! Note!
To minimize electrical emissions and susceptibility to interference from other equipment, and also
to comply with the European EMC directive, all cables connected to the 4 to 20 mA output, serial
output, and relay outputs must be shielded. Additionally, the insulation on all interconnect cables
should be rated for at least 300 volts.
The maximum length of the serial output cable is 15.2 m (50 ft.)
1

2

3

4
6

5
a0010687

Fig. 9:
1
2
3
4
5
6

Grounding shielded cable
Foil shield (width of the "P" clamp)
Ground wire (bare)"P" clamp
Hex nut
Lock washer
Cabinet studPreparation of the shielded cable1.

Remove the outer jacket from the cable to provide enough wire to reach the appropriate
terminal block.

2.

Remove the foil shield, but keep the width of the "P" clamp.

3.

Cut the ground wire to a length of approximately 1.3 cm (0.5").

4.

Wrap the ground wire around the foil several times.

5.

Fit the "P" clamp over the shield. When the clamp is fully closed, there should be a good tightconnection to the foil shield and ground wire.

Installation of the shielded cable
1.

Mount the "P" clamp to the stud closest to where the cable enters the analyzer cabinet.

2.

Connect the cable according to the connection diagram.

+
Data
Common1
2
3
4

4 - 20 mA
Serial dataa0010694

Fig. 10:20

Connection diagram

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Wiring4.1.4

Connecting the relay outputs• Each analyzer has either one or two relay boards.
• Each relay output is rated at max. 0.5 A, 24 VDC/240 VAC due to the current-carrying
limitations of circuit boards.
• Each relay has a single set of form “C” contacts.

12 11 10 9 8 7 6 5 4 3 2 1

C
NO NC
Rel 4

Rel 3

Rel 2

C
NO NC
Rel 1
a0010701

Fig. 11:

Connection diagram

If a second relay board is installed, it is located on top of the first. Its connections will also be fromright to left with relay #5 on the right.

4.2

Post-connection check

Carry out the following checks after electrical connection:
Device status and specifications

Note

Is the exterior of the analyzer or cable undamaged?

Visual inspection

Electrical connection

Note

Does the supply voltage correspond to the data on the nameplate?

230 V AC 50/60 Hz
115 V AC 50/60 Hz

Are current outputs shielded and connected?
Are the mounted cables strain-relieved?
Are the cable types properly separated?

Run power supply and signal lines
separately over the entire travel distance.
Separate cable channels are ideal.

Are the cables routed without loops or crossovers?
Are power supply and signal lines connected correctly according to wiring
diagram?
Are all screw terminals tightened?
Are all cable entries mounted, tightened and leak-resistant?

Endress+Hauser

21

Operation

EZ-TOC II analyzer CA52TOC

5

Operation

5.1

Operating elements
11

10
9
8
12
7
13

14

6

5

4
3

2

1
a0011150

Fig. 12:
Display and operating elements
Feed pump
1
Organic sample pump2
Source selector
3
Acid pump / oxidation pump4
Source pump
5
"Pumps" switch
6"Inorganic carbons" flow meter
7

22

8
9
10
11
12
13
14

"Organic carbons" flowmeter"UV reactor" switch
Power switch
Display and keypad
UV reactor
Condenser column
TIC scrubber (appearance may vary)

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Operation

5.2

Display and keypad

The display shows:• Measured value• Programming menus.
• Status• Failures and warnings

a0011112

Fig. 13:

Display and keypad

Key assignment:• The number keys allow you to enter numeric values.
• The arrow keys allow you to move through the menus on the display. The menu item currently
selected will be flashing.
• The PROGRAM key starts the program menus.
• The CLEAR key will return the display to the previously entered value, if you have not pressed
ENTER.
• The EXIT key returns you to the next higher level menu. If you keep pressing the EXIT key, youwill return to the normal operation display.
• The ENTER key saves the flashing entry.

Endress+Hauser

23Commissioning

EZ-TOC II analyzer CA52TOC

6Commissioning

6.1

Function check# Warning!
• Check all connections for correctness.
• Make sure that the supply voltage is identical to the voltage indicated on the nameplate!

6.2

Programming

6.2.1

COMMANDS menu

Display

Description

Start Calibration
Start Clean
Abort Cal/clean
REAGENT TIMER
Restart Pumps

Start Calibration manually begins a calibration cycle that is just like anauto-calibration. The analyzer will run deionized water and the standard
calibrating solution through its cycle to recalibrate itself.

Start Calibration
Start Clean
Abort Cal/clean
REAGENT TIMER
Restart Pumps
Start Calibration
Start Clean
Abort Cal/clean
REAGENT TIMER
Restart Pumps
Start Calibration
Start Clean
Abort Cal/clean
REAGENT TIMER
Restart Pumps

ENTER TIMESRESET TIMERDISPLAY TIMER

Total Time =XXX Hours
Warning Time =XXX Hours
ENTER TIMESRESET TIMERDISPLAY TIMER

Reset Timer?
YES
NO

ENTER TIMESRESET TIMERDISPLAY TIMER

24

Start Clean manually begins a cleaning cycle just like the auto-clean cycle.

Abort Cal/clean stops a calibration cycle currently in progress. The analyzer
will return to normal operation (measuring TOC). This function will also clear
the following fault conditions if they are present: "Calibration Fail" and "IR
Fault".

REAGENT TIMER leads you to the following submenus.

ENTER TIMES leads you to the next submenu.

Total Time is the time period you expect the analyzer to operate for after you
have filled the reagents.
Warning Time is the time you select near the end of the cycle entered for"Total Time", to warn you that the reagents are running low.
RESET TIMER leads you to the next submenu.

This menu will also appear if you enter a new "Total Time".
YES reloads the timer with the "Total Time" value.
NO returns you to the previous menu.

DISPLAY TIMER leads you to the next submenu.

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Commissioning

Display

Description

Remaining Time(days: hours: minutes)

Start Calibration
Start Clean
Abort Cal/clean
REAGENT TIMER
Restart Pumps

Endress+Hauser

Remaining Time shows the time remaining of the "Total Time".

Restart Pumps puts the analyzer back online (if liquid is available) byrestarting the pumps.
If the analyzer detects a loss of flow, it will stop the pumps after 5 minutes
and the unit will switch to offline status.
This command is also used if the analyzer has gone offline due to a liquid leak.

25

Commissioning

EZ-TOC II analyzer CA52TOC

6.2.2

CALIBRATION menu

Display

Description

STANDARD
INHIBITTIMESMANUALS

STANDARD leads you to the following screen.

Standard = XXXmg/L

STANDARD
INHIBITTIMESMANUALS
TOTAL
LEVEL

Inhibit All Cal/Clean
YES
NO

TOTAL
LEVEL

Cal/Clean Inhibit
Level = XXXmg/L

STANDARD
INHIBITTIMESMANUALS
START
INTERVAL
DELAY

Calibration Start =XX:XX (time) XXX (date)
Clean Start =XX:XX (time) XXX (date)

START
INTERVAL
DELAY

Calib. Interval =XX Hours XX Minutes
Clean Interval =XX Hours XX Minutes

26

This screen lets you set the concentration for the standard solution, Potassium
Hydrogen Phthalate (KHP) or other chemicals, used by the analyzer forcalibration purposes. You enter the value here that corresponds to theconcentration of the solution you make up.
Min. 50% max. 120% of the measuring range.
INHIBIT leads you to the following screen.

TOTAL leads you to the next submenu.

YES will inhibit all automatic calibration/cleaning cycles.

LEVEL leads you to the next submenu.

Enter a level of measured carbon. Above this level, the analyzer continues
monitoring even when it is scheduled for a calibration or cleaning cycle. In
such cases, it is more important to continue to monitor the flow than to go
offline for calibration or cleaning.
TIMES leads you to the following submenu.

START leads you to the following screen.

CALIBRATION START: Enter the start time for the first calibration of theunit.
CLEAN START: Enter the start time for the first cleaning cycle of the unit.
To check the next calibrate/clean cycle start times you may enter this screen
at any time.
The clean cycle should always be run before a scheduled calibration.
INTERVAL leads you to the following screen.

CALIB. INTERVAL: Enter the time between the first calibration and thenext calibration.
CLEAN INTERVAL: Enter the time between the first cleaning cycle and thenext cleaning cycle.

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Commissioning

Display

Description

START
INTERVAL
DELAY

Baseline Delay =XX Minutes
Calib. Delay =XX Minutes
Post-Calib. Delay =XX Minutes
Clean Delay =XX Minutes
Post Clean Delay =XX Minutes

DELAY leads you to the following screen.

BASELINE DELAY: Enter the time period during which the baseline iscalibrated. During this time, deionized water flows through the analyzer toestablish the baseline (0% point of concentration or zero set point).
CALIBRATION DELAY: Enter the time period during which calibration is
performed. During this time, the "standard" solution flows through theanalyzer. The analyzer determines the 100% or full-scale set point.
POST-CALIB. DELAY: Enter the time delay from when calibration ends towhen sample measurement restarts. During this time, the sample solution
flows through the analyzer.
CLEAN DELAY: Enter the time period during which a cleaning cycle isperformed.
POST CLEAN DELAY: Enter the time delay from when the cleaning cycle
ends to when sample measurement restarts. During this time, the sample
solution flows through the analyzer

The following menus are for qualified personnel only.
The menus allow you to adjust the liquid mixtures used to calibrate the unit. These menus are intended for use by skilled
operators, such as a trained specialists from the vendor company, when carrying out a three- or six-month calibration
inspection. These procedures should not be undertaken casually.

!

Note!
Do not perform a manual gas calibration! Manual gas calibration is performed by Endress+Hauser Service.
See the section "Calibration" for detailed calibration instructions.

STANDARD
INHIBITTIMESMANUALS
LIQUID CALIBRATIONGAS CALIBRATIONDISPLAY FACTORSENTER FACTORSSTANDARD
BASELINE

Apply XX mg/L
ENTER When Stable
In = XX.X% Av = XX.X%
Mn = XX.X% Mx = XX.X%

Endress+Hauser

MANUALS leads you to the following submenu.

LIQUID CALIBRATION leads you to the following screen.

STANDARD: This runs the "standard" solution, Potassium Hydrogen
Phthalate (KHP) or other chemicals, through the analyzer to establish thefull-scale or 100% value in the liquid reactor section of the analyzer. Do thisbefore setting the baseline.
The following screen will appear:
In is the "instantaneous" reading.
Av is the "average" reading, which is derived from the previous 30 readings.
Mn is the minimum reading from the last 30 readings.
Mx is the maximum reading from the last 30 readings.

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Commissioning

EZ-TOC II analyzer CA52TOC

Display

Description

You must first prepare a standard that is equal in concentration to the full-scale rating of the unit. When finished, you canreset the "standard" to the calibration standard used in auto-calibration. The value will be close to the full-scale value forthe analyzer. The display should read close to 100% ±5%. Adjust the ORGANIC CARBON air flow to get a reading as
close to 100% as possible.
Analyzers set up for 10 mg/l full scale may be more difficult to adjust because of their sensitivity. It is desirable to havethe organic carbon air flow in the range of 80 to 100 ml/min. If the airflow required to achieve a reading of 100% is
outside this range, adjust the air flow to bring it into the 80 to 100 ml/min range. It is acceptable for the displayedpercentage for average (Av) to fall within a range of 75 to 125%, if this brings the air flow closer to, or within, the 80 to
100 ml/min range.
Increasing the air flow (knob turned ccw) decreases the reading. Decreasing the air flow (knob turned cw) increases
the reading. Allow five minutes between adjustments for the unit to stabilize. The compressed air added to thesystem serves as a gas propellant to move the CO2 through the system, specifically from the ultraviolet reactor to theinfrared analyzer.
Note the following:• When performing a liquid calibration, it takes approx. 10 minutes for a reading to stabilize. This is because changes
made at the "front end" of a system will take some time to work through the system.
• When you increase the air setting, the CO2 reading will decrease. This is because the increased air will effectively
dilute the CO2.
It is not necessary to use a 100% standard. The analyzer will accept standards of 50 to 150% of the full scale. Mix thesolution in accordance with the standard value you have chosen.

STANDARD
BASELINE

Apply DI Water
ENTER When Stable
In = XX.X% Av = XX.X%
Mn = XX.X% Mx = XX.X%
LIQUID CALIBRATIONGAS CALIBRATIONDISPLAY FACTORSENTER FACTORSLIQUID CALIBRATIONGAS CALIBRATIONDISPLAY FACTORSENTER FACTORS
Liq Gain = 1.0000
Liq Offset = 0.0

Unable to Calibrate
Not On-line

Calibration Invalid
Out of Range

28

BASELINE is the setting for 0% carbon content.
See the section "Calibration" for detailed calibration instructions.
The following screen will appear.

The DI (deionized) water contains no carbon; therefore, it is used to set thevalue for the zero setpoint. The value after it has stabilized should be less than
5%. Wait for the Av value to stabilize. The In value may continue to change.

GAS CALIBRATION will be performed by Endress+Hauser Service.

DISPLAY FACTORS leads you to the following screen.

The values in this display are the calibration factors resulting from the lastliquid calibration. The liquid values will change when you perform a manual
liquid calibration or when the analyzer performs an auto-calibration.
Recording these values can give you an indication of aging that may occur inthe analyzer.
If a manual calibration is attempted when the unit is offline, the following
message will appear as soon as the manual calibration command is entered.
("Not on-line" means conditions such as calibration, cleaning, or being offline
due to a fault condition.)
If a manual liquid calibration is not successful because the factors calculated
from it are too far out of range, this message will appear to alert you to thisfact.

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Commissioning

6.2.3

SETUP menu

The SETUP menu is programmed during installation of the analyzer. These menu values are
generally not changed once the analyzer is installed. They should be changed only by qualified
personnel.
Display

Description

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

HH:MM DD:MMM:YY(time)(date)CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

ALARM 1
ALARM 2
ALARM 3
ALARM 4
Alarm 1 Delay =XX MIN TOC

Alarm 1 Level =XXX mg/L TOC

CLOCK leads you to the submenu.

Enter the current time and date here. Enter the month as a number: Jan. = 1,
etc.

ALARMS leads you to the submenu.

ALARM 1 leads you to the next submenu.

A time can be entered using the number keys. This is the time delay which
occurs from when the alarm level (shown on next screen) is reached to when
the actual alarm is activated.
This function can be used to screen out a momentary TOC level that is above
the alarm level. When an alarm level is reached, the actual alarm is activatedonly after the time delay has elapsed.
After setting the time delay, the level menu appears:
Here you can select the level of carbon concentration required to trigger thealarm. What this alarm actually triggers is configured in a later section of the
program. Note the letters TOC after the alarm level. This indicates that theunit is operating in TOC mode. You can set the mode to COD elsewhere in
the program. If the setting is COD, the letters shown in the alarm level menus
will be COD, as there are separate alarm levels for each TOC and COD alarm.
If you switch between modes, the alarm levels will switch to the mode you
selected. Even when a mode is not selected, the alarm levels are still saved.
This means that if you switch back to that mode, you do not have to reenter
the alarm levels.

There are four independent alarms. Selecting ALARM 2, 3, or 4 will show similar screens for each alarm.

Endress+Hauser

29Commissioning

EZ-TOC II analyzer CA52TOC

Display

Description

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGEANALOG 1
ANALOG 2

CURRENT RANGESCALINGCAL/CLEAN ACTIONINHIBIT ACTION
Current Range =0 TO 20 mA
4 TO 20 mA

CURRENT RANGESCALINGCAL/CLEAN ACTIONINHIBIT ACTION
Zero (4 mA) =XXX mg/L
Full-Scale (20 mA) =XXX mg/L
CURRENT RANGESCALINGCAL/CLEAN ACTIONINHIBIT ACTION
Cal/Clean Action =ZERO LEVELHOLD LEVELCURRENT RANGESCALINGCAL/CLEAN ACTIONINHIBIT ACTION
Inhibit Action =ZERO LEVELHOLD LEVEL30

ANALOG OUTPUT leads you to the next submenu:

The ANALOG OUTPUT menus determine the output of a current loop used
to control industrial process equipment. The level of current in the loop varies
with the changing level of carbon measured by the analyzer. Typically, the 0
or 4 mA current point is 0% or baseline, and the 20 mA point is the full scale.
The purpose of this variable current is to provide an adjustable response fromthe process equipment to match the changes measured by the analyzer.
ANALOG 2 is an option that requires installation of additional hardware tooperate. This menu will still be present, even without the hardware.
Selecting ANALOG 1 leads you to the next submenu:
If you select CURRENT RANGE (available only for ANALOG 1) from the
ANALOG OUTPUT menu, the following display will appear:

Whether you select 0 to 20 mA or 4 to 20 mA depends on the requirementsof the process equipment controlled by your analyzer.
ANALOG 2 is 4-20 mA only, and so it is not possible to select a range.

If you select SCALING from the ANALOG 1 (2) menu, the following
display will appear:

This menu sets the zero (baseline) and full-scale (100%) carbon values for the
analog output current. Note that these values are whatever you decide to set
them to.

If you select CAL/CLEAN ACTION from the ANALOG 1 (2) menu, thefollowing display will appear:

The CAL/CLEAN menu determines the level of analog output when theanalyzer is offline (i.e. not measuring the sample) because it is either in acleaning cycle or being calibrated. This menu gives you the option of dropping
the analog output to zero (ZERO LEVEL) during a calibration or cleaning
cycle, or having the output remain at the level it was at when the analyzer
was measuring the sample prior to commencing the calibrate/clean cycle(HOLD). ZERO LEVEL is either 4 mA or 0 mA, depending on the current
range you selected earlier.
If you select INHIBIT ACTION from the ANALOG OUT menu, thefollowing display will appear:

The INHIBIT ACTION menu is similar to CAL/CLEAN ACTION, but isused when the analog output is inactive because the analog inhibit switch has
been activated. This is to prevent unusual changes in the 4 to 20 mA loop that
could have detrimental effects on the operation of equipment controlled by
the loop. Selecting ZERO LEVEL will drop the Analog Output Loop to zero.
Selecting HOLD LEVEL will cause the analog output loop to maintain thesame current as provided from the last valid reading.

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EZ-TOC II analyzer CA52TOC

Commissioning

Display

Description

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGEBAUDDATA BITS
PARITYSTOP BITS
REPEAT RATEBaud =
300
600
1200
2400
4800
9600
BAUD
DATA BITS
PARITYSTOP BITS
REPEAT RATE

Data Bits =
7
8

BAUD
DATA BITS
PARITYSTOP BITS
REPEAT RATEParity =
NONE
EVEN
ODD
BAUD
DATA BITS
PARITYSTOP BITS
REPEAT RATE

Stop Bits =
1
2

BAUD
DATA BITS
PARITYSTOP BITS
REPEAT RATE

Endress+Hauser

SERIAL OUTPUT leads you to the next submenu.

In the SERIAL OUTPUT menus, you make the necessary settings forcommunication with a computer or another digital device.
Selecting BAUD leads you to the next submenu.

Baud rates indicate the speed at which serial data are transmitted from theanalyzer to a remote computer or other digital equipment. Select a Baud rateused by the computer or other digital device at the other end of the line.

Selecting DATA BITS leads you to the next submenu.

Again, select whatever is compatible with the computer or other digital device
used with the analyzer in the installation.

Selecting PARITY leads you to the next submenu.

In this case also, selection depends on the setup of the computer you are usingwith the analyzer.

Selecting STOP BITS leads you to the next submenu.

In this case also, selection depends on the setup of the computer you are usingwith the analyzer.

Selecting REPEAT RATE leads you to the next submenu.

31Commissioning

EZ-TOC II analyzer CA52TOC

Display

Description

Repeat Rate =X H XX M XX S

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

All KeysCalib/Setup Menus
No Password
NEW PASSWORD

The selection you make in the REPEAT RATE menu determines how often
the serial data stream is transmitted from the analyzer. The number entered
here is the time that elapses between the start of one serial data stream andthe start of the next data stream. The unit will accept numbers from 1 second
to 1 hour, 59 minutes, and 59 seconds.
PASSWORD leads you to the next submenu.

All Keys requires that you enter a password to operate any key on theanalyzer. In normal operation, there are only four active keys: PROGRAM,INHIBIT ALARM, INHIBIT ANALOG, and INHIBIT CLEAN/
CALIBRATE. If you press any of these keys, the analyzer will request a
password before performing any of these functions. This prevents
unauthorized persons from operating the analyzer, as knowledge of thepassword is required.
• All Keys:
By entering a valid password, you can press one of the four active keys
followed by another within one minute without having to enter the
password again.
• Calib/Setup menus:
This password mode allows you to perform the functions of the normal
mode keys (inhibit and program) without needing a password. You can also
enter program mode and perform any of the operations under the
COMMANDS menu without a password. You can go into the
CALIBRATION and SETUP menus and view the settings within them.
However, a password is required to change a value or setting.
Once you have entered a valid password and you are working within the
programming menus, you can make additional changes without theanalyzer again requesting a password. If you exit the programming menus
and then return to these menus, the first change you attempt to make will
result in a password request.
• No Password:
This mode allows you to access all functions and menus and to makechanges as desired without any passwords. There are exceptions, however.
You must still have the special password to do gas calibration, and apassword is always required for diagnostics.
• NEW PASSWORD:
Leads you to the next submenu.

New Password =XXXX

Invalid Password

32

NEW PASSWORD allows you to change the password required in one of theabove modes. You should be very careful to record the new password if you
decide to change it.
If you enter the correct pass number (originally 3500), the selection or value
you want to change will be saved in the memory. If you enter an incorrect
pass number, the unit will beep and the following display will appear.
The screen will then revert to the menu in the program that is one level
higher than the menu you were trying to change.

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Commissioning

Display

Description

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

DELAY TIMERELAY ACTIVATIONDELAY 1DELAY 2

Delay Time 1 =Xm
Xs

DELAY TIMERELAY ACTIVATIONRELAY 1RELAY 2RELAY 3
RELAY 4RELAY 5RELAY 6RELAY 7
RELAY 8
AND 1
AND 2
AND 3
AND 4
DELAY 1DELAY 2Endress+Hauser

RELAY OUTPUT leads you to the next submenu:

Selecting DELAY TIME leads you to the next submenu:

If you select DELAY 1 the following screen will appear:

You may enter a time in minutes and seconds. The delay functions can beused to set a time delay between the occurrence of a condition and theactivation of a relay.

When you go to RELAY ACTIVATION, you will find DELAY 1 and
DELAY 2 listed along with the relays. Under each of these is the same list of
conditions as those that can activate relays. You may select any of these
conditions to start the delay. Then, under any of the relays, you can select thatdelay as its activating condition. When the condition occurs, it will activate
the delay. When the time delay has elapsed, the programmed relay isactivated.
Selecting RELAY ACTIVATION leads you to the next submenu:
Note that relays 5 – 8 are optional; not all analyzers will have them.
Note that a "+" (plus sign) appearing to the left of the word "RELAY" or"AND" or "DELAY" indicates that conditions have been programmed toactivate that particular relay, AND, or delay. This allows you to determine
quickly which relays/ANDs/delays have been programmed and which ones
are still available.
If you select any of the relays, the following screen will appear:33

Commissioning

EZ-TOC II analyzer CA52TOC

Display

Description** RELAY X **Alarm 1
Alarm 2
Alarm 3
Alarm 4
Loss Of Flow
Scrub Gas Fail
Reactor Gas Fail
Liquid Leak
Overrange
Calibration
Cleaning
Unit Off-line
Dilution Active
Alarm Inhibit
Analog Inhibit
Cal/Clean Inhibit
Reagent Warning
IR Fault
Power Fail
Calib. FailNo Liquid Calib.
Reactor Fault
Timer 1 (or 2)
Dilution 2
AND 1
AND 2
AND 3
AND 4
DELAY 1DELAY 234

The X in RELAY X is the number of one of the four (or eight) relays available
to you. Alternatively, it is the number of one of the four AND functions or
one of the two DELAYS available in the analyzer.
This list contains all the conditions you can select to activate a particular relay.
• Alarm 1 to 4
These are the level settings you entered for ALARMS earlier. This step
assigns that condition to a specific relay.
• Loss of Flow
The analyzer has an internal flow detector that shuts down the pumps andturns off the UV lamp in the reactor chamber to protect the lamp andchamber. You can also use this condition to send a remote signal.
• Scrub Gas Fail
Indicates that gas is not going through the inorganic scrubber.
• Reactor Gas Fail
Indicates that gas is not going through the UV reactor chamber.
• Liquid Leak
The analyzer has a tray in the bottom with a liquid detector in it. The tray
will catch leaks from the unit and signal this condition.
• Overrange
Indicates that the analyzer is detecting a greater level of carbon than it was
designed to do. For example, if yours is a 1000 mg/l (full-scale) analyzer
and the analyzer is detecting 1050 mg/l, it will activate the overrange
signal.
• Calibration
The analyzer is offline and in a calibration cycle.
• Cleaning
The analyzer is offline and in a cleaning cycle.
• Unit Offline
Indicates that the unit is not measuring TOC. This results from any one ofthree different conditions: Scrub Gas Fail, Reactor Gas Fail, or Loss Of
Flow. This offline condition does not include cleaning and calibration
cycles, even though the unit is not measuring carbon during these
operations. This offline condition results from a fault in the unit.
• Dilution Active
Activates an external (not supplied) dilution pump that will dilute thesample with deionized water whenever the reading exceeds apredetermined point.
• Alarm Inhibit
Refers to the control switch on the keypad. It prevents this function fromoccurring, instead keeping the unit online.
• Analog Inhibit
Refers to the control switch on the keypad. It prevents this function fromoccurring, instead keeping the unit online.
• Cal/Clean Inhibit
Refers to the control switch on the keypad. It prevents this function fromoccurring, instead keeping the unit online.
• Reagent Warning
The reagent timer has counted down to the warning time that you
programmed. It is an indication that the reagents are low and will need tobe replaced soon.
• IR Fault
Indicates a failure in the unit’s IR detector.
• Power Fail
Indicates a failure in the unit’s power supply.
• Calib. Fail
Indicates that the calibration results are out of tolerance.
• No Liquid Calib.
Indicates that the unit has not been calibrated with liquids (standard
solution and DI water). The unit is still using default values for liquidcalibration.
• Reactor Fault
Indicates a fault condition in the UV reactor temperature sensors• Timer 1 (or 2)
Refers to the programmable timers that may be used to activate relay
outputs.
• Dilution 2
Is a second dilution output.

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EZ-TOC II analyzer CA52TOC

Commissioning

Display

Description

The analyzer has one relay board with four "C" contacts. A second relay board is available ( see the section "Accessories").
The relays are unassigned.
To assign an activation condition to a relay:
1.

Select a condition using the arrow key.

2.

Save by pressing ENTER. A "+" sign will appear in front of the condition. The "+" sign indicates the activatedcondition. The relay will be activated whenever the condition becomes true. You can choose one of these conditions
to activate the relay, or you can choose more than one condition to build an "activation list" for that relay. The
conditions will be logically OR’ed together.

To assign a "NOT" condition to a relay:
1.

Select a condition using the arrow key.

2.

Press the "zero" key.

3.

Save by pressing ENTER. A "-" sign will appear in front of the condition. The relay will be activated whenever thecondition becomes false.

To remove a condition:1.

Select a condition with the arrow key.

2.

Save with ENTER. The "+" or "-" sign in front of the condition will disappear.

You can also combine the conditions with a logical AND function:1.

Select "AND 1" or "AND 2" to "AND 4" using the arrow key.

2.

Press "ENTER".

3.

Select the first condition with the arrow key.

4.

Press "ENTER". A "+" sign will appear in front of the condition.

5.

Select the second condition with the arrow key.

6.

Press "ENTER". A "+" sign will appear in front of the condition.

Relay Defaults
Relay 1 — Alarm 1
Relay 2 — Alarm 2
Relay 3 — Loss Of Flow, Scrub Gas Fail, Reactor Gas Fail
Relay 4 — Loss Of Flow, Scrub Gas Fail, Reactor Gas Fail, IR Fault, Calibration Fail, Reactor Fault
Relay 5 — Calibration, Cleaning
Relay 6 — Alarm Inhibit, Analog Inhibit, Cal/Clean Inhibit
Relay 7 — Dilution Active
Relay 8 — Overrange
Power Fail Condition Special Considerations
The power fail condition to activate a relay is a unique condition. When the condition is true, the correct power is nolonger being supplied to the analyzer. Use the NOT condition for the Power Fail condition.

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

ENABLE
CUT-IN LEVEL
CUT-OUT LEVEL
PUMP TIME
CUT-IN TIME
CUT-OUT TIMEDILUTION FACTOR
AUTO LEVEL ADJUSTEndress+Hauser

DILUTION leads you to the next submenu.

ENABLE is a general enable for dilution. The menu below it provides YES
and NO choices. NO will prevent dilution from becoming active under any
circumstances and the other menu choices for DILUTION will have noeffect. Selecting YES will allow DILUTION to operate according to whateversubsequent menu choices you make in the DILUTION menu.

35

Commissioning

EZ-TOC II analyzer CA52TOC

Display

ENABLE
CUT-IN LEVEL
CUT-OUT LEVEL
PUMP TIME
CUT-IN TIME
CUT-OUT TIMEDILUTION FACTOR
AUTO LEVEL ADJUSTENABLE
CUT-IN LEVEL
CUT-OUT LEVEL
PUMP TIME
CUT-IN TIME
CUT-OUT TIMEDILUTION FACTOR
AUTO LEVEL ADJUSTENABLE
CUT-IN LEVEL
CUT-OUT LEVEL
PUMP TIME
CUT-IN TIME
CUT-OUT TIMEDILUTION FACTOR
AUTO LEVEL ADJUSTENABLE
CUT-IN LEVEL
CUT-OUT LEVEL
PUMP TIME
CUT-IN TIME
CUT-OUT TIMEDILUTION FACTOR
AUTO LEVEL ADJUSTENABLE
CUT-IN LEVEL
CUT-OUT LEVEL
PUMP TIME
CUT-IN TIME
CUT-OUT TIMEDILUTION FACTOR
AUTO LEVEL ADJUSTENABLE
CUT-IN LEVEL
CUT-OUT LEVEL
PUMP TIME
CUT-IN TIME
CUT-OUT TIMEDILUTION FACTOR
AUTO LEVEL ADJUSTENABLE
CUT-IN LEVEL
CUT-OUT LEVEL
PUMP TIME
CUT-IN TIME
CUT-OUT TIMEDILUTION FACTOR
AUTO LEVEL ADJUST36

Description
CUT-IN LEVEL is the carbon level that activates external dilution. When
this point is reached, the condition DILUTION ACTIVE becomes true, andthat condition can be used to activate one of the relays. Note that you mustselect DILUTION ACTIVE and one of the relays in the RELAY OUTPUT
menu for anything to actually happen here. Once the condition to activate arelay has been true for a certain time period, the analyzer enters dilution
mode.
CUT-OUT LEVEL is the carbon level below which dilution will be turned
off if it has been activated. Note that operation of this function is also affectedby the AUTO LEVEL ADJUST option in this same DILUTION menu. If you
select YES for AUTO LEVEL ADJUST, the cut-out level will be the actual
carbon level in the undiluted stream, not the carbon level of the diluted
sample that is flowing through the analyzer.

PUMP TIME is the programmable time that occurs in tandem with the
CUT-IN TIME. It is used through a relay to control an additional external
pump in certain high-range configurations.

CUT-IN TIME is the time it takes the unit to transition into dilution. This
time starts one minute after the carbon level rises above the cut-in level. How
the transition occurs depends on the setting for AUTO LEVEL ADJUST. If
NO was selected, the CUT-IN TIME will simply be the minimum time theanalyzer will be in dilution mode. The unit will not be able to exit from
dilution mode during this time, even if the carbon level falls below the
CUT-OUT LEVEL. If AUTO LEVEL ADJUST is set to YES, this time willbe the time period for which the analyzer holds the carbon level reading. This
time should be set for the proper interval required for the diluted sample towork its way through the analyzer. CUT-IN TIME can be set from one
minute to 59 minutes.
CUT-OUT TIME may also be set from one to 59 minutes. It will not affectthe operation of the unit if NO was selected for AUTO LEVEL ADJUST. In
this mode, dilution will end when the carbon level falls below the CUT-OUTLEVEL for at least one minute. When YES is selected for AUTO LEVELADJUST, the CUT-OUT TIME becomes the transition time out of dilution
after the carbon level has fallen below the CUT-OUT LEVEL. This value
should be set to the time it takes for the full-strength sample to work its way
through the analyzer. During this time period, the carbon reading will be held
constant.
DILUTION FACTOR is the ratio of dilution water to the sample. If threetimes as much dilution water is added to the sample, the ratio of dilutant tosample is 3:1. The concentration in the resulting solution is ¼.
The maximum allowable value is 50:1

AUTO LEVEL ADJUST makes the analyzer display the actual carbon levelin the sample stream when dilution is turned on. AUTO LEVEL ADJUST
works by multiplying the carbon value measured in the diluted sample by the
dilution factor. The displayed value and the value transmitted in the serial
stream are affected by AUTO LEVEL ADJUST. Alarm settings,
Calibrate/Clean values and the analog output settings will not change.

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Commissioning

Display

Description

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

Averaging Display Over90 Seconds

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

TIMER 1TIMER 2

ON TIMEOFF TIMESTATUS(STOP)(START TIME)
On Time =XX H XX M XX SON TIMEOFF TIMESTATUS(STOP)(START TIME)

Off Time =XX H XX M XX SON TIMEOFF TIMESTATUS(STOP)(START TIME)

Endress+Hauser

The analyzer takes a reading every second. However, the displayed value canbe a reading averaged out over a much longer time period. In someinstallations, a "smooth" output that does not show small, rapidly changing
events is preferred. Other installations may need a quick response to a suddenchange. An example of this would be installations where spills are possible
and it is necessary to respond quickly to them. DISPLAY AVERAGING
allows you to choose the time period for averaging the displayed reading, as
well as the analog output current.
DISPLAY AVERAGING leads you to the next submenu.

Enter a number between 1 and 200. The displayed value will be an averagevalue taken over the selected time period. For a "smooth" response, select alarge number. For example, 180 will be three minutes. It will reduce small
peaks and valleys and will give a smoother output that still shows an overall
trend. The factory setting (default) is 90 seconds.
TIMERS leads you to the next submenu.

The menus available for defining the operation of both timers are identical.
TIMER 1 leads you to the next submenu.

ON TIME leads you to the next submenu.

The ON TIME (output activated) menu allows a time to be entered in hours,
minutes, and seconds. This time may be a maximum of 12 hours, 59 minutes,
and 59 seconds.

OFF TIME leads you to the next submenu.

Operation of the OFF TIME menu is the same as that of the ON TIME
menu.

START TIME leads you to the next submenu.

37

Commissioning

EZ-TOC II analyzer CA52TOC

Display

Description

Start Time =(time) (date)

Enable Start Time =YESNO

Stop Timer 1
YES
NO

ON TIMEOFF TIMESTATUS(STOP)(START TIME)
Timer 1 Status
Start: START PENDING
Start Time:(time) (date)

Relay Number
12345678
AND Number
1234

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

SELECT MODE
ENTER LK

TOC-1 Stream
* COD

38

The START TIME menu allows you to enter a future time at which the timer
will start operation. The START TIME menu will appear when the timer is
not running. This includes the periods when the timer is stopped and when astart time has been entered but not yet reached, with the result that the timer
has not started. During this pending time, the START TIME menu can beaccessed to allow the start time to be changed to a different time. Once thestart time is reached and the timer starts, the START TIME menu is nolonger available, as it is not needed.
Once you have entered a start time, a menu will appear asking if you want toenable the start time. Selecting YES will allow the analyzer to start the
program at the programmed time.
Once you have entered and enabled a start time, the STOP menu will appear.
This option allows you to stop the timer at any time. You can stop the timer
after entering and enabling a start time, even if the start time has not yet beenreached. You can also stop the timer after it has begun to run. The STOP
menu is the only way to stop a timer. Otherwise, the timer will continue torun indefinitely once it has started until you select the STOP menu. An
additional menu under the STOP menu requires that YES be selected inorder to stop the timer.
STATUS leads you to the next submenu.

The STATUS menu consists of two screens of data regarding the status of thetimer. The top line of the first screen identifies the timer as 1 or 2. The secondline is the current state of the timer. It can be on, off, stopped, or "startpending". The third and fourth lines depend on the status of the timer. If it isstopped, nothing will appear on these lines. If a start time is pending, theselines will show the start time. If the timer is running, these lines will show theremaining time in the current on or off cycle.
The second screen of the STATUS menu is as shown in the following display:
This screen shows which of the relays and AND conditions have been
programmed to be activated by this timer. The second line shows thenumbers of the relays this timer has been programmed to activate. The
numbers 1 through 8 can appear on this line. The fourth line can have thenumbers 1 through 4 for the four possible AND conditions.
MODE leads you to the next submenu.

SELECT MODE leads you to the next submenu.

TOC-Stream is the standard operation: measuring TOC and displaying it.
Another parameter that can be measured is COD (Chemical Oxygen
Demand). This may be correlated to TOC in a laboratory. If you want todisplay such a correlated value, choose *COD. The analyzer will still measure
TOC but will multiply the measured value by a factor and display it as *COD.
The factor used is entered in the next menu, ENTER LK.

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Commissioning

Display

Description

SELECT MODE
ENTER LK

COD Multiplier (LK) =X.X

ENTER LK leads you to the next submenu:

Here you enter the multiplier that will change the TOC number to be
displayed as a COD value. The range for the multiplier is 0.1 to 10.0.

Use Ø for decimal point

CLOCK
ALARMSANALOG OUTPUTSERIAL OUTPUTPASSWORDRELAY OUTPUT
DILUTIONDISPLAY AVERAGINGTIMERSMODELANGUAGE

EnglishGermanItalianFrench

6.2.4

LANGUAGE leads you to the next submenu.

Select the appropriate language.

DIAGNOSTICS menu

The DIAGNOSTICS menus are used by Endress + Hauser Service to troubleshoot the instrument.

Endress+Hauser

39Commissioning

EZ-TOC II analyzer CA52TOC

6.3

Communication

The analyzer has an RS-232 serial output with a repeating string of ASCII characters. The following
is a description of the characters and their location in the string:Characters

Description

1 -6

This is the full-scale TOC in mg/l (ppm). There are no leading zeroes.
Unneeded characters are left blank.

7

Blank (unused character)8 - 13Current TOC of "Stream 1" as a decimal fraction of the full scale, with 1.000
being the maximum (e.g. 0.7124).

14

Blank (unused character)

15 - 20

Current TOC of "Stream 2" as a decimal fraction of the full scale, with 1.000
being the maximum (e.g. 0.7124). It will be zero if it is a single stream system.

21

Blank (unused character)22 - 24

Operating status of the unit. It will always begin with the character "A:". The
following states are:0 = on-line
1 = cleaning
2 = calibrating
3 = offline
4 = manual calibrating
5 = auto gas calibrating IR analyzer(e. g. A:0)40

25

Blank (unused character)

26 - 38

Current time and date. Note that the sixth character will always be "B".
(e. g. 12:34B22SEP04, which is 12:34 PM on the 22nd of September, 2004)

39

Blank (unused character)

40 - 52

Start time of the next cleaning cycle. The sixth character will always be "C".
(e. g. 12:00C23SEP04)

53

Blank (unused character)

54 - 66

Start time of the next calibration cycle. The sixth character will always be "D".
(e. g. 13:00D23SEP04)

67

Blank (unused character)

68 - 75

Activating level for "Alarm 1". It will always begin with character "E".
(e. g. E:8000)

76

Blank (unused character)77 - 84

Activating level for "Alarm 2". It will always begin with character "F".
(e. g. F:6000)

85

Blank (unused character)Endress+Hauser

EZ-TOC II analyzer CA52TOC

Commissioning

Characters

Description

86 - 93

Inhibit level "Calibrate/Clean". It will always begin with character "G".
(e. g. E:8000)

94

Blank (unused character)95 - 102

Number of minutes remaining for the reagent timer. It will always begin withcharacter "H". (e. g. H:144000)

103

Blank (unused character)104 - 138

These are all the letters of the alphabet representing the conditions that can
activate relays. Some letters are used twice, so pay attention to the character
location.
If the letters appear in upper case, the condition is true (condition has
occurred). If they appear in lower case, the condition is false (has notoccurred).
The conditions are as follows:
A = Alarm 1
B = Alarm 2
C = Alarm 3
D = Alarm 4
E = Loss of flow detected
F = Loss of scrub gas detected
G = Loss of reactor gas detected
H = Liquid leak detected
I = Overrange
J = Unit currently in calibration
K = Unit currently cleaning
L = Unit offline
M = Dilution active
N = Alarm inhibited
O = Analog output inhibited
P = Calibration / cleaning inhibited
Q = Reagents low warning
R = IR fault
S = Power failure
T = Calibration fault
U = No liquid calibration
V = Reactor fault
W = Timer 1
X = Timer 2
Y = Stream 1
Z = Stream 2
A = Stream 1 active
B = Stream 2 active
C = 2 stream pass / fail
D = AND 1
E = AND 2
F = AND 3
G = AND 4
H = Delay 1
I = Delay 2

Endress+Hauser

139

Blank (unused character)

140

Carriage return

41

Commissioning

42

EZ-TOC II analyzer CA52TOC

Characters

Description

141

Line feed

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Maintenance

7

Maintenance

It is necessary to perform maintenance on a regular basis to keep the analyzer operating efficiently.

# Warning!
You must have a thorough understanding of the maintenance procedures before attempting service.
All maintenance procedures described in this section should be performed only by a qualified service
technician. Incorrect service could cause inaccurate operation, and could also create safety hazards.
Preventive maintenance is divided up as follows:• 14-day (biweekly) maintenance• 30-day (monthly) maintenance• 90-day (quarterly) maintenance• 180-day (semiannual) maintenance (performed by Endress+Hauser Service)• 360-day (annual) maintenance (performed by Endress+Hauser Service)
As you use your analyzer, you may find that some inspections need to be done at a different
frequency than our suggested time intervals. Make adjustments according to your specific needs,
but always perform maintenance on a regular basis!

Endress+Hauser

43

Fig. 14:44

SodiumPersulfate

Dilution
Fluid

Acid

Calibration
Solution

Oxidizer
Pump

Dilution
Pump

Acid
Pump

Feed
Pump

T'Fitting'

Deionized
Water

Manual3-Way
Valve

Loss ofFlow
Detection

SourcePump

Electric
2-Way
Valve

3 into 1
NC Selector
Valve

Internal

Clean
Solution

ManualSampleSampleOut

SampleIn

External

Inorganic
CarbonScrubber

Flow
Switch

Check
Valve

T'Fitting'

T'Fitting'

Organic
SampleGLS

Organic
SamplePump

Trap/
Condenser

GLS

GLS CO 2In

Drain

Vent

GLS Vent 1
GLS Vent 2
GLS Drain
System Drain

Flow
SwitchCapillary
Tube

Check
Valve

UV
ReactorOrifice

2- WayNC Valve

Check
Valve

Factory set to200-250 cc/min

0-.5
PSI

Flow
Regulator

Purge In

Flow Meter
with Flow Regulator

T'Fitting'
T'Fitting'

T'Fitting'

Air
FilterSampleCell

IR
Detector

T'Fitting'Purge Out

Hydrophobic
FilterFlow Meter
with Flow Regulator

Nafion Tube
Gas Dryer

Internal

CO2 Removal
Column(Optional)

System
Drain

IR
Vent

System
Vent

External

Customer
Supplied
Compressed
Air

Maintenance
EZ-TOC II analyzer CA52TOC

Flow diagram
Use this diagram as a reference when replacing or reconnecting tubing.

Flow diagram

a0011148-enEndress+Hauser

EZ-TOC II analyzer CA52TOC

Maintenance

7.1

Biweekly maintenanceEvery two weeks you must replace the standard solution and the deionized water. Prepare thestandard as described in the section "Preparing chemicals".

7.2

Monthly maintenance

The following tasks must be performed:• Replenish reagents• Reset reagent timer• Inspect entire unit

7.2.1

Replenish reagentsEvery thirty days you will need to replenish the acid and oxidizing reagents used in the analyzer.
These are 10% (v/v) phosphoric acid (H3PO4) and sodium persulfate (Na2S2O8). Prepare thesolutions as described in the section "Preparing chemicals”.

7.2.2

Reset reagent timer

Follow the steps below to reset the reagent timer. For detailed information, refer to the instructionsin the section "COMMANDS menu".
From the COMMANDS menu, select REAGENT TIMER to display the menu shown below:
ENTER TIMESRESET TIMERDISPLAY TIMER

Selecting RESET TIMER leads to the following submenu:
Reset Timer?
YES
NO

Select YES to reload the timer with the "total time" value from the ENTER TIMES menu.

7.2.3

Inspect entire unit

• Check that the display reads ON LINE.
CARBON: XX mg/l
STATUS: ON LINE
Internal Temp = XX °C(present time), (date)• Check that all pumps are running.

a0010802Fig. 15:

Check slot for pump rotation

The pumps do not rotate rapidly, and they do not all turn at the same speed. However, they should
all be rotating in a counterclockwise direction.

Endress+Hauser

45

Maintenance

EZ-TOC II analyzer CA52TOC• Check that the reactor is still active.

# Warning!
Protect your eyes. Do not look directly at the UV lamp when the unit is running. UV radiation cancause serious eye damage, as well as skin inflammation.
Check the reactor by looking briefly into the top of the black or blue cylinder. The fittings in thebottom of the reactor should give off a pale light, indicating that the UV lamp is operational. Liquidand gas output from the reactor should also be present.
• Check for leaks.

# Warning!
Disconnect the power supply to the analyzer before servicing. This is done either at the breaker
panel or by pulling the fuses inside the cabinet. Always shut down the analyzer before inspecting
the tubing inside the cabinet. Drain all liquid lines and flush with water before replacing any tubing.
The analyzer has a built-in leak detector that will warn of serious or prolonged leakage.
Nevertheless, inspect all tubing and connections to make sure there is no evidence of leakage.
Pay particular attention to the tubing that passes through each pump. This tubing is under thegreatest stress because it is flattened against the side of the case by the pump rollers each time thepump rotates.
1

2
1

1

a0010803

Fig. 16:
1
2

46

Routing of pump tubing through rollers

Rollers
Tubing routed through pumpEndress+Hauser

EZ-TOC II analyzer CA52TOC

Maintenance

7.3

Quarterly maintenance

The following tasks must be performed:• 30-day maintenance routine• Replacement of all pump tubing• Internal cleaning of analyzer• Leak-testing of scrubber gas lines• Leak-testing of UV reactor gas lines• Leak-testing of IR purge / gas dryer counterflow lines• Manual liquid calibration• Automatic cleaning• Automatic calibration• Running zero water• Running span (full-scale) standard solution• Running alarm standards
The following materials will be required to perform the 90-day maintenance routine:• Tubing (for the pumps and for test purposes)• TOC standard solutions made up to exceed Alarm 1 level and Alarm 2 level and to equal the fullscale (span)• Appropriate general cleaning agents• Vacuum cleaner• Multimeter

7.3.1

Replacement of pump tubing# Warning!
Do not attempt to disassemble the pumps when power is running. You could injure your fingers ifthey get caught in the pump rollers.

! Note!
To avoid the possibility of making incorrect tubing connections, remove only one pump head at atime. Change the tubing and then reconnect that pump.
Preparation
1.

Remove the acid and persulfate lines from their respective bottles.

2.

Feed water (either DI or tap) through the analyzer for about 10 minutes to purge the two
chemicals from the system.

Disassembling the pumps

Endress+Hauser

1.

Shut off the analyzer.

2.

Remove the thumbscrews from the pump head.

3.

Disconnect the pump tubing

4.

Pull the pump head straight off the analyzer.

47

Maintenance

EZ-TOC II analyzer CA52TOC

2

1a0010817

Fig. 17:

Side view of pump body

1
2

Separate pump halves along this line
Drive shaft

5.

Holding the pump in both hands, separate the halves by twisting each half in opposite
directions and pulling apart gently.

6.

Remove the old tubing.

! Note!
When you disassemble the pump, note the two white washers between the pump shaft andthe bearings. These washers prevent binding when the pump is operating. Do not discard thewashers. Be sure to reinstall them when reassembling the pump.
Reassembling the pumps
1.

Press the new tubing around the rollers, working your way around all three rollers and thepump body. Note that it does not matter which half of the pump contains the rollers. Try tocenter the tubing on the rollers as much as possible.

2.

Press the two halves of the pump body back together. If the strength of the new tubing
prevents the two halves from coming together completely, it may be helpful to rotate the pumpshaft with a pair of pliers while you press the two halves together.

3.

Reinstall the pump head.

4.

Reconnect the tubing.

5.

Reattach the four thumbscrews.

Repeat this process for all the other pumps on the analyzer.

7.3.2

48

Internal cleaning of analyzer

1.

Shut off the analyzer.

2.

Vacuum the inside of the cabinet. Be careful not to disturb any of the glassware, tubing or
wiring inside the cabinet.

3.

Clean the analyzer window with water-based spray-on window glass cleaner and a soft cloth.
Never use paper towels, cleaners containing abrasives, petrochemical-based solvents, or
halogenated solvents. Paper towels and abrasives will scratch the window, which is made ofpolycarbonate. Petro-solvents and halogenated solvents may damage the plastic.

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Maintenance

7.3.3

Leak-testing of gas lines

a0010816

Fig. 18:

Leak detection

Leak check the scrubber, UV reactor, and IR purge gas lines as follows:1.

Make up a solution of liquid soap and water in a small container. The solution should be quite
strong, with 25 % or more soap.

" Caution!
Be very careful when working inside the unit to avoid contact with any electrical connections.
2.

With a small, soft brush, paint the solution onto the connection points between the gas tubing
and the glassware, reactor, and IR analyzer (Fig. 18).

3.

Check for the formation of bubbles at the connection between the tubing and the fittings. Any
bubbles found indicate leakage.

4.

Replace any leaking tubing.

5.

Clean non-leaking joints with a sponge or soft cloth to prevent the buildup of soap residue.

7.3.4

Manual liquid calibration

This procedure allows you to verify that the analyzer can determine the correct carbon
concentration for both zero (deionized water) and TOC standard solutions. To perform a manual
liquid calibration, proceed as follows:
Preparation
1.

Mix a 1-liter container of the full-scale standard solution used in your analyzer (10, 100, 500,
1,000, 5,000, or 10,000 mg/l) according to the correct procedure.

2.

Fill a 1-to 2-liter container with deionized water. Place both containers (the DI water and thestandard solution) near the analyzer.

3.

Connect a 1.5 to 3 m (5 to 10 ft.) piece of PFA tubing to the container of standard solution and
the MANUAL SAMPLE input on the side of the analyzer.

4.

Turn the SOURCE SELECTOR (located below the pumps) clockwise from the 3 o’clock
position to the 6 o’clock position. This will allow the analyzer to draw in the standard solution
through the MANUAL SAMPLE port.

Performing manual liquid calibration1.

Select the CALIBRATION menu. - Press ENTER.

2.

Select the MANUALS menu. - Press ENTER.

3.

Select LIQUID CALIBRATION. - Press ENTER.

4.

Select STANDARD. - Press ENTER.

5.

The display will show:
Apply XX mg/L
ENTER When Stable
In = XX.X% Av = XX.X%
Mn = XX.X% Mx = XX.X%

Endress+Hauser

49

Maintenance

EZ-TOC II analyzer CA52TOC

6.

Wait until the display shows close to 80 to 90% of the full scale. This may take 20 to 30
minutes.

7.

Adjust the ORGANIC CARBONS air regulator (located close to the power switch) to display
100 % ±3 %. Wait at least 5 minutes between adjustments, and only turn the regulator by 1/8
to 1/4 of a turn at a time. Turning the slot clockwise increases the TOC percentage displayed,while turning the slot counterclockwise decreases the TOC percentage displayed. When the
Av (average) reading is 100 % ±3 % of the full-scale value, press ENTER.

8.

Select BASELINE. - Press ENTER.

9.

The display will show the following:
Apply DI Water
ENTER When Stable
In = XX.X% Av = XX.X%
Mn = XX.X% Mx = XX.X%

10. Remove the PFA tube from the container of standard solution, and rinse the last few inches ofthe end of the tube with DI water. Then insert the tube into the container of DI water.
11. Wait 30 to 40 minutes or until the displayed value falls to 0 + 3 % of the full scale. When thedisplayed value is stable within the specified range, press ENTER. If a value below 3 % cannot
be obtained:– Check for air leaks.
– Get fresh DI (deionized water) in a clean container.
– Run cleaning solution for one hour and then try again.
12. Press EXIT. - Select DISPLAY FACTORS. - Press ENTER.
Liq Gain = 1.0000
Liq Offset = 0.0

13. The first line of the display shows the liquid gain. It is acceptable if it is in the range of 0.75 to
1.25. However, the preferred range for gain is 0.9 to 1.1. If the value is outside the preferred
range, you may need to clean the analyzer thoroughly and have a gas calibration performed.
The second line indicates the liquid offset. This value should be between –125 and +125. A
value outside this range also indicates the need for maintenance. For 10 ppm full-scale units,
the acceptable liquid gain may be as high as 2.5 to 3.0.
14. The display will now return to the SELECT menu. Press EXIT four times to return to the main
display.

7.3.5

Automatic cleanThis procedure allows you to verify that the auto-clean feature is operating correctly.
1.

Connect a tube from a container of cleaning solution to the CLEAN SOLUTION inlet on theright-hand side of the analyzer.

2.

Select COMMANDS. - Press ENTER.

3.

Select START CLEAN. - Press ENTER.

4.

Press EXIT to return to the standard display.

The display will show the following:
Status: Cleaning. The next line will flash between Internal Temp: XX°C and Cleaning
Delay: XX m. The period of time the analyzer stays in clean mode is user-programmable in the
CALIBRATION – TIMES menu.
The analyzer will now begin an auto-clean. After the clean cycle is finished, the unit stays in clean
mode for a specified amount of time for a post-clean cycle (this time is also user-programmable).
During the post-clean period, the unit pumps the sample through the system to return the system
to where it was before the cleaning cycle. The unit will then return to normal operation, and thedisplay will show Status: On Line.
50

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EZ-TOC II analyzer CA52TOC

Maintenance

7.3.6

Automatic calibration

This procedure allows you to verify that the auto-calibrate feature is operating correctly. You willneed the following:• Standard solution (appropriate for your unit, 10, 100, 500, 1,000, 5,000, or 10,000 mg/l
carbon)• Zero or baseline solution (preferably deionized water)
Procedure1.

Using tubing, connect these two solutions to the Calibration and Deionized water inlets on
the right-hand side of the analyzer.

2.

Select COMMANDS. - Press ENTER.

3.

Select START CALIBRATION. - Press ENTER.

4.

Press EXIT to return to the standard display.

The display will show:
Status: Calibrating. The next line will flash between Internal Temp: XX°C and Calib
Standard: XX m. The period of time the analyzer stays in calibration mode is user-programmablein the CALIBRATION – TIMES menu. You can use the same time for auto calibration or manual
calibration.
The analyzer will first run a gas calibration, which will last about five minutes.
The unit will then begin pumping in zero (baseline) solution, and the display will show: Reading
XXXX mg/l and Calib Baseline XX m. The value should fall to 0 to 2 mg/l. This process willtake 20 to 30 minutes at minimum. The analyzer will then pump in the standard solution. This will
also take 20 to 30 minutes. The exact period of time depends on the length of time programmed
into the unit and how the unit was configured. The display should show the full-scale reading for
the unit, Reading XXXX mg/l.

7.3.7

Alarm Standards" Caution!
When testing for alarms, temporarily disable any equipment that would respond to an actual alarmin order to prevent an unintentional response. The easiest way to do this is to pull the terminal
blocks from the relay boards. Turn off power before working inside the cabinet.
This procedure allows you to verify that the alarm and relay outputs are operating correctly. To run
the alarm standards, you can follow the same procedure used to verify operation using the standard
solution. However, this time use solutions formulated to have a higher concentration than isnecessary to activate the alarms.

" Caution!
Once you have completed the alarm tests, make sure to reactivate any equipment you disabled
to test the alarms. This guarantees the correct response in the event of an actual alarm.

Endress+Hauser

51

Accessories

EZ-TOC II analyzer CA52TOC

8

Accessories

90 / 180 day maintenance kit• Includes the tubing for all pump head sizes• Order number: 71092036
Set of service parts for annual maintenance PA-2
• Order number: 71013847
Set of service parts for annual maintenance PA-3
• Order number: 71013848
PA-2 piping without solenoids• Order number: 71093894
PA-3 piping without solenoids• Order number: 71093895
Solenoids for PA-2/PA-3, 115V AC• Order number: 71093896
Solenoids for PA-2/PA-3, 230V AC• Order number: 71093897
Carrier gas generator• Order number 115 V AC: 71092115• Order number 230 V AC: 71092116

52

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Troubleshooting

9

Troubleshooting

9.1

Messages

The messages that are displayed indicate faults or other conditions. Each message will appear for
two seconds. The unit cycles continuously through all current messages.
Message

Unit

Description

Reagents low

Hours, minutes

The time remaining before the reagents run out is less than thewarning time.

C/C Inhibit

Minutes

The time remaining on the Calibrate/Clean Inhibit function. This
timer (60 minutes) starts counting down when you press the C/C
Inhibit switch. At zero the inhibition is lifted.

Cleaning Delay

Minutes

The unit is performing a cleaning cycle. The time shown is the timeremaining in the first part of the cleaning cycle during which the unit
is pumping cleaning solution through the system.

Post Cleaning

Minutes

The unit is currently in a cleaning cycle. The time shown is the timeremaining in the last part of the cycle during which sample is being
pumped through the analyzer. The measured carbon level will appear
on line 1. Since the unit is not on-line, it will not transmit themeasured carbon level.

Calib. Baseline

Minutes

The analyzer is currently performing a calibration. The time shown isthe remaining time during which deionized water is pumped throughthe system.

Calib. Standard

Minutes

The analyzer is currently performing a calibration. The time shown isthe remaining time during which the calibration standard (potassium
phthalate) is pumped through the system.

Post Calib.

Minutes

The analyzer is currently performing a calibration cycle. The timeshown is the remaining time in the second half of the cycle during
which sample is pumped through the system. The measured carbon
level will appear on line 1. Since the unit is not on-line, it will nottransmit the measured carbon level.

Time to Clean

MinutesThis is the time in minutes before the next cleaning cycle starts. Thismessage will appear on the display one hour before the start of thecleaning cycle. This message warns service personnel that they may
need to inhibit the Calibrate/Clean cycle.

Time to Calibrate

MinutesThis is the time in minutes before the next calibration cycle starts.
This message will appear on the display one hour before the start ofthe calibration cycle. This message advises service personnel thatthey may need to inhibit the Calibrate/Clean cycle.

Alarm Inhibit

MinutesThis is the time remaining during which the analyzer inhibits alarms.
This timer starts counting down from 60 minutes when the alarm
inhibit switch is activated.

Internal Temp.

Degrees C

This is the temperature of the air inside the cabinet.

Scrub Gas Fault

This indicates that gas flow to the inorganic scrubber has stopped.

Reactor Gas Fault

This indicates that gas flow to the ultraviolet reactor chamber has
stopped.

Calib IR

Endress+Hauser

MinutesThis is the beginning of an auto-calibration cycle. The IR analyzer iscalibrated with zero gas.

53Troubleshooting

EZ-TOC II analyzer CA52TOC

Message

Unit

Loss of Flow Fault

Analog Inhibit

The analyzer has detected a loss of liquid flow through the sourcepump.
Minutes

Dilution Active

Holding Carbon

54

Description

This indicates the remaining time during which the analyzer inhibits
the analog current output. It starts counting down from 60 minutes
when the INHIBIT ANALOG switch is activated.
If external dilution has been enabled and the dilution cut-in level isexceeded, a signal is sent to start the external pump. This message
indicates that the pump signal has been sent.

Minutes

If external dilution has been enabled and the unit is transitioning intoor out of dilution mode, the displayed carbon level will be frozen
until the dilution conditions stabilize. This message displays theremaining time in minutes during which the level will be maintained.

Overrange

The measured carbon level has exceeded the full-scale for the unit.

Calibration Fail - Liq

The correction factors for liquid calibration obtained by the unit fromthe last auto-calibration sequence were out of range and were notsaved.

Liquid Leak

The analyzer has detected liquid accumulating in the drain pan at thebottom of the unit.

IR Fault

The analyzer has lost communication with the IR bench.

Not Liq Calibrated

This message indicates that a liquid calibration has not been
performed on this unit. Changing the full-scale value of a unit
invalidates its liquid calibration. When the full scale is changed, theliquid calibration values will revert to the default values, and thismessage will appear.

Reactor Fault

The unit is not reading values from temperature sensors inside thereactor. This is probably due to a failure in the sensors. The heaters in
the reactor will shut down to protect the reactor.

Reactor Not To Temp

The reactor is not at the proper operating temperature.

Liq Detector Not Cal

The liquid detector has not been calibrated.

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Troubleshooting

9.2

Spare parts

Spare parts for pumps

1

4
5

7

9

8

10

2

3

6

a0011733

Fig. 19:
Pump/motor assembly (from below)
1
Dilution pump head (only some configurations)2
Source pump head3
Source motor
4
Acid pump head5
Persulphate pump head

Endress+Hauser

6
7
8
9
10

Acid/persulphate motor
Organic sample pump head
Organic smple motor
Feed pump head
Feed motor

Pump/Motor

10 mg/l

100 mg/l

500 mg/l

1,000 mg/l

5,000 mg/l

10,000 mg/l

1

N/A

N/A

N/A

N/A

71091954

71091954

271091955

71091955

71091955

71091955

71091955

71091955

371091813

71091809

71091809

71091809

71091809

71091809

471091952

71091952

71091952

71091952

71091952

71091952

571091952

71091952

71091952

71091952

71091952

71091952

671091807

71091807

71091807

71091807

71091807

71091807

771091955

71091954

71091952

71091952

71091952

71091952

871091811

71091811

71091811

71091808

71091808

71091808

971091955

71091954

71091952

71091952

71091952

71091952

1071091810

71091809

71091809

71091809

71091809

71091809

55

Troubleshooting

EZ-TOC II analyzer CA52TOC

Additional spare parts

4
6

10
11
1
3
5
2

9

8

7

a0011768

Fig. 20:

56

Spare parts position

Endress+Hauser

EZ-TOC II analyzer CA52TOC

Endress+Hauser

Troubleshooting

Position

Description and contents

Order number
Spare parts kit

1

Glassware condenser column

71092016

2

Liquid detector assembly

71092021

3

Glassware inorganic C

71092015

3

Glassware sparging column

71092018

4

Glass reactor without UV lamp

71092033

5

Pinch valve 2/2-way 24 V DC

71092047

6

IR detector with flag digital

71092029

7

Filter assembly 1/8" NPT

71092038

8

Glassware system GLS

71092017

8

Glassware fast response GLS

71092019

9

Nafion gas dryer tube

71092353

10

UV lamp assembly

71092032

11

Reactor nut passivated71092354

Description and contents

Order number
Spare parts kit

Air flow switch monitor 0.5 A

71091958

Filter hydrophobic IR detector

71092039

Filter gas converter coalescing

71092040

Filter gas converter charcoal

71092041

Filter gas converter dust removal

71092042

All fittings interior

71092356

All fittings exterior

71092357

Extra fittings dual stream

71092358

57

Troubleshooting

EZ-TOC II analyzer CA52TOC

9.3

ReturnIf 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"!

9.4

Decommissioning

To decommission the analyzer, proceed as follows:1.

Connect the sample, acid and pesulfate lines to deionized water or tap water.

2.

Run the analyzer for at least two hours with all sources connected to deionized water or tap
water.

3.

Once the two hours have elapsed, turn off the analyzer. Turn off the power and disconnect thepower line. Allow the gas supply to continue flowing.

4.

Disconnect all the liquid lines and drain the analyzer completely.

5.

Disconnect the persulfate line at the pump outlet and drain the reactor.

6.

Turn off the gas supply to the analyzer and disconnect the gas lines from the analyzer.

7.

Make sure no remaining liquid is left anywhere inside the unit. This includes tubing,glassware and the reactor.

8.

Clean and dry any spillages inside the cabinet or at the bottom.

When shipping the analyzer, use the original shipping crate. If the original shipping crate is no longer
available, proceed as follows:
1.

Place the analyzer on its back and bolt it to a strong pallet.

2.

Construct a strong enclosure around the analyzer using plywood with a minimum thickness of
10 mm (3/8").

9.5

Disposal

The device contains electronic components and must therefore be disposed of in accordance withregulations on the disposal of electronic waste.
Please observe local regulations.

58

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EZ-TOC II analyzer CA52TOC

Technical Data

10

Technical Data

10.1

Input

Measured variable

TOC or TC

Measuring range

10.2

Endress+Hauser

VersionMeasuring range

A

0.015 to 10 mg TOC / l

B

0.1 to 100 mg TOC / l

C

0.5 to 500 mg TOC / l

D

10 to 1000 mg TOC / l

E

50 to 5000 mg TOC / l

F

100 to 10000 mg TOC / l

OutputOutput signal

0/4 to 20 mA

Interface

RS 232 unidirectional

Alarm

Two programmable alarm levels per channel with up to 8 programmable type C relays
Type C relay: SPDT switch, isolated contacts; each contact is rated at 0.5 A @ 24 V DC /230 V AC. Relay board with 4 relays is part of the system.

Programmable outputs

Up to 8 customer-programmable outputs on type C relays. Can be programmed to output
any combination of multiple system parameters (including the four alarms).

Display

4-line, 20 characters per line, backlit liquid crystal display (LCD)

59

Technical Data

EZ-TOC II analyzer CA52TOC

10.3

Power supply

Supply voltage

115 V AC ±10%, 50/60 Hz, 2 A, 230 VA
230 V AC ±10%, 50/60 Hz, 1 A, 230 VA

Fuses

Supply voltage

Fuses

230 V AC2 x microfuse 1.25 A, 250 V, slow-blow

115 V AC

1 x microfuse 3.0 A, 250 V, slow-blow

10.4

Performance characteristics

Accuracy±1.5 % for TOC concentrations ranging from 0 to 75 % of the full scale±2.5 % for TOC concentrations ranging from 75 to 100 % of the full scale

Response timeLess than 8 minutes to t90 at 100 mg/l configuration TOC

Repeatability±1 % of full scale

Drift±1 % of full scale over 72 hours without calibration at 20 °C (68 °F)

Temperature stabilityLess than 2% of full-scale drift over ambient range of 10 to 30 °C (50 to 86 °F)

Inorganic carbon removal ≥ 95 %, when using standard TIC scrubber≥ 98 %, when using ultra TIC scrubber

10.5

Ambient temperaturerange> 0 to 40 °C (> 32 to 104 °F)

Humiditymax. 90 %Ingress protection

IP 54

Storage conditions

Store in dry rooms only. Use appropriate packaging to store.

10.6

Process

Medium inlet pressure

Unpressurized; low overpressure of max 0.2 bar (2.9 psi) is permitted.

Medium outlet pressure

Unpressurized exhaust

Suspended solids

For particle sizes ≥ 200 μm, an appropriate sample preparation (e.g. PA-2 or PA-3) isrequired. 3 % maximum concentration of suspended solids by volume.

Flow volume

Max. 50 ml/min at 60 Hz

Reagents

1.5 M Na2S2O8 (sodium persulfate), 10% (v/v) H3PO4 (phosphoric acid) or 5% HNO3
(nitric acid), each in deionized water.
Consumption: 19.7 l (5.2 US gal) / month each

10.7

60

Environment

Mechanical construction

Weightapprox. 73 kg (160 lbs)

Housing

IP 54

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EZ-TOC II analyzer CA52TOC

Index
A

M

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Alarm standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Automatic calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Automatic clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Alarm standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Automatic calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Automatic clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Biweekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cleaning of analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspect entire unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Leak testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Manual liquid calibration . . . . . . . . . . . . . . . . . . . . . . . 49
Monthly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 45
Quarterly maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacement of pump tubing . . . . . . . . . . . . . . . . . . . . 47
Replenish reagents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Reset reagent timer . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Manual liquid calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Menu
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Monthly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B
Biweekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

CCALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation and function . . . . . . . . . . . . . . . . . . . . . . . 24
Chemicals preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cleaning of analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cleaning solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 24
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connection
Gas sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Relay outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Signal outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DN
Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

O

E

P

Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Phosphoric acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Post-connection check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Potassium hydrogen phthalate . . . . . . . . . . . . . . . . . . . . . . 14
Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Preparing chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump tubing replacement . . . . . . . . . . . . . . . . . . . . . . . . . 47

G
Gas sources connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

I
Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Immunity to interference. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Incoming acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect entire unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 8, 10

K
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

L
Leak testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Endress+Hauser

Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Q
Quarterly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

R
Reagent quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Relay outputs
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replenish reagents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Reset reagent timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Return. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 58

61

EZ-TOC II analyzer CA52TOC

S
Safety icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Signal outputs
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sodium persulfate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TTechnical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

U
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

W
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

62

Endress+Hauser

a
0
0
0
2
5
8
7

Declaration of Hazardous Material and De-Contamination
Erklärung zur Kontamination und Reinigung
Please reference the Return Authorization Number (RA#), obtained from Endress+Hauser, on all paperwork and mark the RA#
clearly on the outside of the box. If this procedure is not followed, it may result in the refusal of the package at our facility.
Bitte geben Sie die von E+H mitgeteilte Rücklieferungsnummer (RA#) auf allen Lieferpapieren an und vermerken Sie dieseauch außen auf der Verpackung. Nichtbeachtung dieser Anweisung führt zur Ablehnung ihrer Lieferung.

RA No.

Because of legal regulations and for the safety of our employees and operating equipment, we need the "Declaration of Hazardous Material
and De-Contamination", with your signature, before your order can be handled. Please make absolutely sure to attach it to the outside of the
packaging.
Aufgrund der gesetzlichen Vorschriften und zum Schutz unserer Mitarbeiter und Betriebseinrichtungen, benötigen wir die unterschriebene"Erklärung zur Kontamination und Reinigung", bevor Ihr Auftrag bearbeitet werden kann. Bringen Sie diese unbedingt außen an der
Verpackung an.
Type of instrument / sensor
Geräte-/Sensortyp____________________________________________

Serial number
Seriennummer ________________________

Used as SIL device in a Safety Instrumented System / Einsatz als SIL Gerät in SchutzeinrichtungenProcess data/Prozessdaten

Temperature / Temperatur_____ [°F] _____ [°C]
Conductivity / Leitfähigkeit ________ [µS/cm]

Pressure / Druck_____ [psi] _____ [ Pa ]Viscosity /Viskosität _____ [cp] _____ [mm2/s]

Medium and warnings
Warnhinweise zum Medium
Medium /concentration Identification flammable
CAS No.
Medium /Konzentration
entzündlich

toxic
giftigcorrosiveätzendharmful/irritant
gesundheitsschädlich/
reizendother *
harmlesssonstiges* unbedenklich

Process
mediumMedium imProzess
Medium forprocess cleaning
Medium zur
Prozessreinigung
Returned partcleaned with
Medium zur
Endreinigung* explosive; oxidising; dangerous for the environment; biological risk; radioactive* explosiv; brandfördernd; umweltgefährlich; biogefährlich; radioaktiv
Please tick should one of the above be applicable, include safety data sheet and, if necessary, special handling instructions.
Zutreffendes ankreuzen; trifft einer der Warnhinweise zu, Sicherheitsdatenblatt und ggf. spezielle Handhabungsvorschriften beilegen.
Description of failure / Fehlerbeschreibung ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Company data /Angaben zum Absender

onta XIV

Company /Firma ____________________________________________________________________________________
Address / Adresse__________________________________________________________________________________________________

Phone number of contact person /Telefon-Nr. Ansprechpartner:____________________________________________
Fax / E-Mail ____________________________________________Your order No. / Ihre Auftragsnr. ____________________________“We hereby certify that this declaration is filled out truthfully and completely to the best of our knowledge.We further certify that the returnedparts have been carefully cleaned. To the best of our knowledge they are free of any residues in dangerous quantities.”“Wir bestätigen, die vorliegende Erklärung nach unserem besten Wissen wahrheitsgetreu und vollständig ausgefüllt zu haben. Wir bestätigen
weiter, dass die zurückgesandten Teile sorgfältig gereinigt wurden und nach unserem besten Wissen frei von Rückständen in gefahrbringender Menge sind.”www.endress.com/worldwide

BA424C/07/en/06.09
71085882
Printed in Germany / FM+SGML 6.0 / DT

71085882