Installation Manual 02/2008
Contents
1. 4 INSTALLATION SET UP The tubing can be shortened to your application Shorter tubing provides faster response time Sample water pressure must be a least 0 5 bar 7 0 psi but not greater than 7 bar 100 psi A pressure regulator located inside the Analyzer protects the spiral quartz tube from damage by excessive inlet pressure The pieces of clear tubing are to be connected from the BYPASS OUT and from the OXIDIZED OUT ports to the user s drain at atmospheric pressure without bends or kinks in the lines Likewise these two pieces of tubing can be shortened although this will have no effect on performance ANALOG OUTPUT The two terminal connections on the left hand side of the terminal strip on the back panel can be used for a self powered 4 20 mA output This ouput can be configured for remote use of TOC most common resistivity or temperature signal The maximum load resistance is 500 ohm ALARMS Two sets of alarm connections Normally Open Normally Closed and common are provided on the same terminal strip Each alarm can be independently configured as either NO Normally Open or NC Normally Closed ALARM 1 ALARM 2 NO1 COM NC1 NO2 COM NC2 Each alarm output is driven by a SPDT relay rated at 0 4A 120 VAC or 2 0A 30 VDC See CHAPTER 3 CONFIGURATION for more information USER INTERFACE PRINTER Two RS232 connections are available and located on the rear panel of the anal2. Remove the round plate on the back panel of the analyzer Unplug the UV lamp lead Pull the lamp straight back loosening it from its socket and removing it from the unit The reverse procedure is used to install the new lamp Grasp the new lamp at its outboard end being careful not to touch the glass and insert the lamp in the socket If the glass portion of the lamp has been exposed to fingerprints or contaminants clean the lamp with a high purity grade of methanol and a scratch free cloth or towel Replace the round plate 10 Connect the power cord 11 Turn power ON The UV time must now be cleared in the software so that the timer will start with 0 hours for the new lamp The UV TIME CLR is accessed as follows Press MENUS Scroll to 12 MAINTENANCE using the down key Press Enter and change Password Factory Default is 0000 using the UP key Select MAINTENANCE 4 4 using UP DOWN key Scroll to 11 Other Setup using the DOWN key Press ENTER and Toggle ON using UP DOWN key Press ENTER Press NEXT to access 5 UV TIME 5 UV TIME UVONTIME 0020 UV CHG TIME 4000 UV TIME CLR OFF Select UV TIME CLR using the DOWN key 22 MAINTENANCE UV TIME UV ON TIME 0020 UV CHG TIME 4000 UV TIME CLR OFF e Press ENTER and toggle UV TIME CLR to ON using the UP DOWN key and press ENTER UV ON TIME will reset to 0000 e UV TIME CLEAR will automatically return to OFF after clearing e Pre
3. SYSTEM COMFIG 1 Sys Name 0000 Print T unit eer Program Ver Xa Using the down key move the cursor to Print T unit Press enter Using the up key change the unit to sec min or hour Press enter Press save Select yes by using the 12 CONFIGURATION up key Press enter Note Changing Print T unit will reset the print time to 01 Press the esc key twice to return to the title screen ANALOG 4 20 mA OUTPUT In the MAIN menus 2 screen Select 6 4 20 mA SETUP ANALOG SETUP Output ppb 4mA Lmt 000 0 20mA Lmt 100 0 The Output options are as follow ppb TOC ppb Mohm Resistivity Mohm cm C Temperature C Hold Holds current value Used for 4 20 mA calibration Not Select Analog signal configured output not used None No configuration output not used In the above display the 4 20 mA output is configured for TOC The 4mA output represents 0 0 ppb TOC and 20 mA represents 100 0 ppb TOC These limit values are user selectable with values of 000 0 to 999 9 AUTO START In the MAIN Menus Refer to 11 SYSTEM CONFIG 2 CALENDAR SETUP SYSTEM CONFIG1 SYSTEM CONFIG2 MAINTENANCE Press ENTER SYSTEM CONFIG 2 Auto Start OFF Print SYS Conf OFF History Clear OFF When AUTO START is set to OFF the operator must push START to initiate the measuring process When it is set to ON the measurement process begins any time the unit goes from the unpowered to the powered state This
4. UV ON v Wait for 2 minutes AA TOC measurement displayed SYSTEM CHECK FAILED 37 550 OPERATION CHART Measurement Mode MEASUREMENT MODE Flowchart shows Start up System Check sequence and menu screens available during Measurement Mode PRESS THORNTON MENUS Key 550 TOC Analyzer P Ver X xx To Main Menus page START STOP Setup Parameter Select UP Key Parameter Select SYSTEM CHECK DOWN Key Parameter Select Please Wait NEXT Key Parameter Select or Page Down Calibration ENTER Key Enter after each ee RESIST 18 20 MQ cm J Parameter Select SYS CHECK FAILED Push Stop key SYSTEM CHECK PASSED Syst UV WARMING UP ystem Please Wait Check RESIST 18 20 MQ cm Measurement Result TOC 200 32ppb RES 18 21 MQ cm TMP 25 6 C NEXT Alarm Setpoint Screen ALM1 450 5 ppb ESC NEXT a TOC 200 32 ppb gt BE ALM 10 3 Moh Indication of Alarm 10 3 Mohm Measurement Trend RES 18 21 MQ cm r UV replacement TF 1 234 RF 0 987 TMP 25 6 C BR SS t TIME TOC RES TP b UV TIME 200 Hours ALM1 H UV Pael 10 30 75 25 18 20 25 0 ei EE Read Only Values 11 00 78 38 17 69 25 1 au i NEXT 11 30 79 54 17 25 25 3 unng measurement cannot be changed in a N these two screens this display alternate ERROR 16 re TMP1 OVER Mi ENTER ENTER L J Indication of Error Measurement Trend Check
5. 3 R MR C TH Calibration Doing Press ENTER again BOARD CALIBRATION 1S2 Re KRe TH BOARD CALIBRATION 1S2 Rc KRec THe 3 RE MR C TH Short Press Enter S3 R MR C TH Calibration Doing Remove the Resistor Assemblies from S1 and S2 as well as the sensor cable connector for S3 Insert Assembly C into the connector for S3 see Figure 3 Figure 3 Printed Circuit Board S A ES MQ S3 O Assembly C IN S1 KSE CH OUT S2 Press ENTER resulting in the following display BOARD CALIBRATION 1S2 Rc KRc THe BOARD CALIBRATION S182 Re KRe THe S3 OR MR C TH Calibration Doing s3 Re MRv C TH R 2M Press Enter Remove Assembly C from the S3 connection and replace with Assembly D see Figure 4 CALIBRATION 27 Figure 4 Printed Circuit Board Ma S3 2M O S 100 KQ S IN S1 Assembly D C 8 OUT S2 Press ENTER resulting in the following display BOARD CALIBRATION BOARD CALIBRATION S182 Re KRc THe S182 Re KRc THe 3 OG MR CG TH S3 Rc Mie C TH Calibration Doing 2M 1000p Press Enter Replace Assembly D with Assembly E which includes a capacitor see Figure 5 Figure 5 Printed Circuit Board Q SS Fe MQ S3 E S Se 1000 pF 2 MQ aN io TENS gt 100 ka OUT S2 Press ENTER for
6. ITEM ppb RELAY High On HIST 00 CONFIGURATION 11 ALARM X 1 OR 2 MODE CONFIGURATION ITEM Select output parameter ppb TOC Mohm Resistivity C Temperature of sample water ERset Error None no output RELAY Definition of relay activation Low Off Relay off at lower than set point Low On Relay on at lower than set point High Off Relay off at higher than set point High On Relay on at higher than set point If Erset is selected in parameter relay activation is automatically set to ON HIST This sets the Hysteresis associated with the alarm set point A value from 0 to 99 can be entered HIST XX 0 to 99 PRINT SET UP If an optional printer is used set up the printing of measurement data as follows In the MAIN Menus 2 screen Select 5 Print Setup Print Setup Use of History Wrt and Nr Of Data are Print Time 01 Sec explained in OPERATION History Wrt OFF Nr Of Data 0000 Print time is the interval between printing in seconds minutes or hours This display shows an interval of 1 To change this value move the cursor to the appropriate digit with the NEXT key then UP or DOWN to change the value Ranges for print intervals are 1 99 seconds 1 99 minutes and 1 99 hours all in increments of 1 sec min or hr This same time also determines Trend Data display see OPERATION To program the units of the Print Time and Trend Data go to 10 System Configuration 1 Press Enter
7. 000 R F 1 000 Select T and enter the known value of TOC The processor will compare this to the instrument value and calculate a T F TOC Factor which is a multiplier and adjust the instrument reading to conform to the known value 30 CALIBRATION CHAPTER 8 ADVANCED CONFIGURATION ADVANCED START UP METHODS The CONFIGURATION and OPERATION methods described previously should be adequate for pure and ultrapure waters resistivity generally in the 10 18 MQ cm range with relatively low levels of TOC However at higher levels of TOC such as encountered in some Reverse Osmosis product water recycle and reclaim rinse water an advanced configuration technique may be necessary for proper operation The indication that the standard procedure may need modification is if the System Check results in a display SYSTEM CHECK FAILED rather than advancing to the UV lamp stabilization stage The purpose of the System Check sequence is to zero out any differences between Sensor 1 and Sensor 2 before the UV oxidation process begins After the START key is pressed the system waits for one minute and then examines the absolute difference between the S1 and S2 conductivity readings If that absolute value is less than Calib No 1 value GEE TABLE ON NEXT PAGE the display will read System Check OK If the difference is not less than Calib No the system will wait 20 seconds and read the measurement again If necessary thi
8. 0010 0010 0006 Calib No 2 0050 0550 0010 If the System Check fails after five tries the processor reads the value of S3 which measures the resistivity of the incoming water sample If the reading of S3 indicates the incoming water is less than 10 MQ cm but greater than 0 05 MQ cm lt 20 uS cm the processor will set the absolute value of the difference between S1 and S2 to zero The System Check will be indicated as PASSED The UV lamp is automatically turned on and allowed to stabilize for approximately 2 minutes The system then starts measuring and indicating TOC If the resistivity of the incoming water is lt 0 05 MQ cm conductivity gt 20uS cm the display will indicate System Check Failed Error 2 is activated and the unit will not measure TOC This error indication can be disabled on the 4 screen of OTHER SETUP menus 4 MEASURE PARA 2 RESERVE2 0000 RESERVE3 1000 Sensor Status 0000 Select Sensor Status using the DOWN key Press ENTER Using the UP key change Sensor Status from 0000 to 1000 to disable Error 2 Press Save to write this change to the EEPROM Press ESC to return the display to the TITLE screen Press START and after the System Check sequence the unit will measure and display TOC e f system check fails again set Reserve2 to 0010 as described on next page 32 ADVANCED CONFIGURATION If the resistivity of the incoming water is 10 MQ cm or above the System Check not
9. EE 24 ANALOG OUTPUT CALIBRATION EE 24 HEES EECHER eege dee 25 BOARD CALIBRATION EE 25 MEASUREMENT VERIEIGATIONIGAUIBRATION 29 CHAPTER 8 ADVANCED CONFIGURATION sssssssssssssssssecssesssseessseesseesseeessseessseeres 31 ADVANCED START UP METHODS 31 Te Me Ee 33 TOG CURVE E 34 APPEND EE 36 KEY DISPLAY FUNCTIONS EE 36 SYSTEM CHECK SEQUENCE deiere deene Are Sieten d ee ee e dee dcee dee Be e en nnne 37 550 OPERATION CHART Measurement Mode sssssssssnnnnneeeseesserrnnreensserrrrrenn 38 550 OPERATION CHART Setup Mode 39 550 OPERATION CHART Setup Mode Maintenance menus ssssseeeeeeesseeeeee 40 550 OPERATION CHART Maintenance Mode Other Setup menus 00s0nne0000 41 OPTIONAL PRINTER DIP SWITCH SETTINGG 2 cc cceceesseeeeseeseeeeeenenseeeeees 42 SPECIFICATIONS vasea aiaosa asenaan aaar aaea Ee euer 43 ACCESSORIES AND REPLACEMENT PARTS ecceeeeeeeeeeeeeeeeeeeeeseseeeeeeeneeeeeees 44 CE DECLARATION OF CONFORMITY cc ecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeees 45 DECLARATION OF CSA COMPLIANCE 2 ccccceseeeeeeeeeeeeeeeeseeneeeeeeseneeeeeeseeneeeeeeseenes 46 APPLICABLE REQUIREMENT EE 46 WARRANTY soicisisciecnetstssnnntesnindie nea cndeaniaveiaueweesdasnctwotsseuteads eeniudewosansdenccientauesuertenadiwedas 47 CHAPTER 1 GETTING STARTED INTRODUCTION Total Organic Carbon measurement is recognized in many industries as an important and some cases
10. For Factory or Service use only TOC OFFSET 0000 NEXT APPENDIX OPTIONAL PRINTER DIP SWITCH SETTINGS Dip Switch Settings for optional Printer model Seiko DPU414 Software DIP SW1 Switch Function Setting Meaning No 1 Input Method OFF Serial 2 Printing Speed ON High 3 Auto loading ON On 4 CR function OFF Carriage return 5 DIP SW setting command ON Enable 6 Print Density OFF 100 7 Print Density ON 100 8 Print Density ON 100 Software DIP SW2 Switch Function Setting Meaning No 1 Print Mode ON Normal Printing 40 Columns 2 User Defined Characters ON On back up 3 Character type ON Ordinary Characters 4 Zero Font ON 0 5 International Character Set ON American 6 International Character Set ON American 7 International Character Set ON American 8 International Character Set OFF American Software DIP SW3 Switch Function Setting Meaning No 1 Data Bit length ON 8 Bit 2 Parity permission ON Without 3 Parity condition ON Odd 4 Flow control ON H W BUSY 5 Baud Rate OFF 9600 bps 6 Baud Rate ON 9600 bps 7 Baud Rate ON 9600 bps 8 Baud Rate ON 9600 bps 42 APPENDIX SPECIFICATIONS Ambient Temp Humidity Location Display Analog outputs Outputs Alarm outputs Alarms displayed Voltage Current Size Weight Sample connections Wetted Parts Printer Print out Printer
11. Mode ee Ke SE S 0 Push ENTER Key to indicate after the vum 7838 17 69 251 TIME Then view the past record of 11 30 7954 1725 25 3 Measurement values with UP DOWN Keys 38 APPENDIX 550 OPERATION CHART Setup Mode Back to Measurement Mode or Title Screen press ESC key once SETUP MODE From Measurement Mode or Title Screen ALARMH MODE ITEM ppb RELAY High On HIST 00 gt ALARM 2 MODE ITEM ppb 2 Setup RELAY LowOn Main menus screen 1 3 L uer o J 1 ALARM MODE ALARM VALUE gt 2 ALARM 2 MODE ENTER Alm 1 100 0ppb 3 ALARM VALUE Am 3 018 0ppb 4 ALARM DELAY gt NPH AM NG J ALARM DELAY Amt 00 sec Am2 00sec a J PRINT SETUP e EC Print Time 01 min History Wt OFF Nr of Data 0100 Se J ANALOG SETUP Output ppb 7 4mALmt 000 0 Main Menus screen 2 3 A E 4000 J 5 PRINT SETUP SE 6 ANALOG SETUP ANAL 7 ANALOG CALIB ENTER 4mA LOW 1000 8 UV TIME 20mAH 1000 HOLD 00 A d J g D UV TIME UVTIME 2000 UV TOTAL 04251 d g N ESC CALENDAR SETUP y yy mmdd 2003 06 03 Main Menus screen 3 3 i d For Service SYSTEMCONFIG1 __ 9 CALENDAR SETUP ENTER SysName 1000 10 SYSTEM CONFIG 1 kl Print T Unit min 11 SYSTEM CONFIG 2 Program Ver 1 xx 12 MAINTENANCE E J SYSTEMCONFIG2 Auto Start OFF To Maintenance Menu Print SYS Conf OFF
12. START key and the System Check cycle will commence After about 3 min the display will indicate SYSTEM CHECK PASSED and that the UV is ON This is for simulation only the lamp is not actually powered Then after about 2 min the measurement screen appears Pushing the START STOP key again returns the display to the TITLE screen Other functions can be examined and values such as alarm set points can be changed for purposes of demonstration Refer to CONFIGURATION and also the Operation Flow Chart in the APPENDIX When finished return to the Playing Demo screen to turn Demo OFF 16 DEMONSTRATION MODE CHAPTER 5 OPERATION POWER ON Turn on the power at the switch on the rear panel of the Analyzer THORNTON 550 TOC Analyzer TITLE Screen will appear as shown High Ver x xx temperature units display 550 HT and SX units display 550 SX BEFORE MEASURING Before starting to measure be sure the flow rate is adjusted to 20 ml min unless otherwise specified for your application MEASURING Push START to initiate the System Check and Measure process SYSTEM CHECK SYSTEM CHECK is blinking The analyzer Please Wait does an automatic zeroing to correct for any drift RESIST 18 20 MQ cm en SYSTEM CHECK PASSED now solid UV WARMING UP UV Warming Up is blinking Please Wait UV Lamp is stabilizing during this period RESIST 18 20 MQ cm TOC 200 32 ppb Primary Measurement Display RES 18 21 MQ cm Measureme
13. alarm contacts Refer to the specifications in the back of this manual for details regarding these outputs GETTING STARTED 3 CHAPTER 2 INSTALLATION SET UP LOCATION The Thornton 550 TOC Analyzer is to be installed in a dry environment with a relative humidity lt 80 non condensing and with ambient temperature between 5 and 40 C 41 to 104 F on a flat horizontal surface The sample inlet line should be fitted with an isolation valve The OXIDIZED SAMPLE OUTLET and BYPASS SAMPLE OUTLET tubes are led to waste or a water reclaim system at atmospheric pressure without any obstructions in the tubing ELECTRICAL CONNECTIONS A power outlet must be available within 3 ft 1 m when using the 3 pronged power cord supplied with the analyzer An adapter for the power cord may be necessary for outlets of different configurations depending on the country in which the unit is installed The unit requires a power source between 100 and 240 VAC at either 50 or 60 Hz Maximum power consumption is 50 W with optional printer installed SAMPLE TUBING CONNECTIONS Three pieces of 2 5 m 8 ft tubing are supplied with the unit Two pieces are relatively clear and the third PFA or similar Teflon material is opaque The Teflon tubing is used for connection from the sample water line to the SAMPLE INLET port on the back panel of the Analyzer Hardware is to be assembled on the tubing as shown below for connection of the tubing to its port
14. and move the asterisk to item 5 PRINT SETUP Press ENTER to enter this menu PRINT SETUP ANALOG SETUP ANALOG CALIB UV TIME Press Enter Print Setup Print Time 10 sec History Wrt OFF Nr of Data 0010 18 OPERATION Select Nr Of Data using the DOWN key and press ENTER Move the cursor using the NEXT key and change to the desired number of most recent data lines you wish to print with the UP DOWN keys Press ENTER Next select History Write using the UP key press ENTER and toggle ON using the UP DOWN keys Press ENTER The number of data lines you selected will print out Push ESC twice to return to the Measurement Display ALARM SETPOINT SCREEN From the Measurement Screen the Alarm Set point Screen can be accessed pressing NEXT twice see APPENDIX This display shows the set point values for Alarms 1 amp 2 These are read only and cannot a E be changed from this screen TF and RF are TF 1 234 R F 0 987 values from 6 TOC Calib in MAINTENANCE UV TIME 200 Hours 2 4 UV TIME is the total number of hours the present lamp has been used NEXT returns the display to the measurement screen ALARM INDICATION If an alarm condition is present or occurs during measurement an alarm message will appear in the measurement display For example TOC 800132 This indicates that Alarm 1 a high alarm has FAAO SA Pee been activated UV indicates that the RES 18 21 MQ TMP 25 6 C recomme
15. interval Power TOC Performance 5 40 C 5 80 RH Non condensing Industrial Environment Indoor LCD with back light displays TOC resistivity temperature and operation error indications One 4 20mA DC Output is selectable for TOC or resistivity or temperature Two SPDT contacts for Hi Alarm Lo Alarm and Error Rated 0 4A 120VAC 2 0A 30VDC UV lamp replacement Alarm Error Alarm both on LCD 100 240 VAC 50 60 Hz 50W max 12 8 327 mm W x 6 6 167 mm H x 13 8 350 mm D 17 6 Ib 8 kg 0 25 in 6 mm tube fittings 316 SS PVDF high quality quartz glass Thermal Serial dot SEIKO Model DPU414 TOC Resistivity Temperature Date and Time 1 99 seconds 1 99 minutes 1 99 hours adjustable in increments of 1 6 VDC provided by analyzer Model Designation 550 HT Measurement 0 1 1000 ppb Range Repeatability Resolution Detection Limit Linearity Accuracy Water Quality Resistivity Conductivity Sample Water Temperature Particle Size Flow Rate Pressure Sample Water MDL Min Detection Limit Temperature Accuracy RTD in Conductivity sensors Values expressed in terms of Slope defined as TOC recovered vs TOC injected based on tests performed using 0 1 ppb lt 10 ppb TOC 1 gt 10 ppb TOC 0 01 ppb 0 1 ppb 1 00 0 05 gt 0 5 MQ cm lt 2 0 uS cm 0 05 18 2 MQ cm 0 055 20 uS cm 15 90 lt 100 um 20 ml min 7 100 psi at Inlet 0 1 ppb 0
16. page down to 11 SYSTEM CONFIG 2 using the NEXT and DOWN keys CALENDAR SETUP SYSTEM CONFIG 1 SYSTEM CONFIG 2 MAINTENANCE Press ENTER key SYSTEM CONFIG 2 Auto Start Print SYS Conf History Clear Select Print SYS Conf using the DOWN key and pressing ENTER Toggle ON using UP DOWN keys and press ENTER All configuration parameters in the database will now be printed through the printer port CONFIGURATION 15 CHAPTER 4 DEMONSTRATION MODE The Thornton 550 can be run in the Demonstration Mode to illustrate and allow practice in changing some of the parameters prior to actual use of the instrument While the measurement value cannot be changed other parameters such as alarm set points can be altered To access the Demo Mode go to 12 Maintenance using the Menus NEXT and DOWN keys CALENDAR SETUP SYSTEM CONFIG 1 SYSTEM CONFIG 2 MAINTENANCE After entering the Password FACTORY default is O000 using the UP and ENTER keys the first screen maintenance 1 4 will display MAINTENANCE 1 4 1 Demo Mode On Off 2 Sensor View 3 EEPROM Setup The default selection is 1 Demo Mode On Off ENTER will display the Demo ON OFF screen as follows Playing Demo Demo Mark Off Use UP to toggle to ON Go back to the title screen by pressing the ESC key 3 times In the lower right corner of the display DEMO will appear If it does not the unit is not in demonstration mode Push the
17. screens 1 4 thru 4 4 C History Clear TORF see next page APPENDIX LUnkey eee Numerical Change DOWN key Numerical Change Move the Cursor ENTER Key Confirm the Set Numerical Value Alarm 1 Setup ltem Chooses parameter to alarm on Relay Activation state when setpoint is reached HIST Histeresis Alarm 2 Setup ltem Chooses parameter to alarm on Relay Activation state when setpoint is reached HIST Histeresis Alarm Value Configures Setpoint values Designates what alarm parameter s and what mode the activated alarm is configured to Alarm Delay Number of seconds before alarm triggers relay activation Print Setup Configures time interval for data pt collection For writing data pts to printer Determines the number of data pts for History Write function Analog Setup For assigning measurement parameter And values of 4 and 20 mA signal See Configuration Analog Output Calibration Fro 4 20mA Output calibration SEE Chapter 2 Installation For output and loop calibration UV Time Time of operation of present UV lamp Total operating time of Analyzer Calendar Setup Set Date and Time See Configuration System Configuration 1 System name See Configuration Printer time interval in sec min hr Current Software version loaded System Configuration 2 If ON meas begins when power applied Toggle ON to print out configuration data Toggle ON to clear trend histo
18. 3 C samples of known concentrations of organics Designates sample water quality requirements to meet stated TOC performance specifications shown Designates range of conductivity measurement only SPECIFICATIONS ACCESSORIES AND REPLACEMENT PARTS Part No Description 139 003 Thermal Printer Serial Interface 6VDC Supplied with power cord interface cable with connectors and manufacturers user s manual 139 005 Resistor Kit Board Calibration 550 HT 129 010 Replacement UV Lamp 185 nanometer 129 002 Replacement Power Cord three prong 1 5 m 5 ft long 44 ACCESSORIES AND REPLACEMENT PARTS CE DECLARATION OF CONFORMITY We Mettler Toledo Thornton Inc 36 Middlesex Turnpike Bedford MA 01730 hereby declare in conjunction with the original equipment manufacturer that all 550 TOC Analyzers to which this declaration relates is in conformity with the following European harmonized and published standards at the date of this declaration EN 61326 Emissions EN 55011 Group Class A and Immunity IEC 61010 1 Safety LVD This declaration is based on complete test data and technical documentation relating to the tests performed per above standards as noted CE DECLARATION OF CONFORMITY 45 DECLARATION OF CSA COMPLIANCE Declaration of CSA Compliance Mettler Toledo Thornton Inc 36 Middlesex Turnpike Bedford MA 01730 hereby declares that all 550 TOC Analyzers are eligible to bear the official CSA Ma
19. ATION 9 Push the NEXT key to view the 2 page of the main menus as shown here PRINT SETUP ANALOG SETUP ANALOG CALIB UV TIME Push the NEXT key again to see the 3 main menus as shown here 9 CALENDAR SETUP 10 SYSTEM CONFIG 1 11 SYSTEM CONFIG 2 12 MAINTENANCE The above menus are the 12 twelve main menus used for set up configuration and maintenance of the 550 TOC Analyzer CALENDAR First set the Calendar by pushing the MENUS key Once at the 1 menu screen push the NEXT key until you reach the 3 menus screen shown below 9 CALENDAR SETUP 10 SYSTEM CONFIG 1 11 SYSTEM CONFIG 2 12 MAINTENANCE If necessary move the to 9 CALENDAR SETUP using the DOWN key Press ENTER Calendar Setup yy mm dd 2003 07 20 hh mm ss_ 11 20 35 This is a 24 hour clock Press ENTER to access the yy mm dd fields Use the NEXT key to move the cursor to the number to be changed Use the UP DOWN keys to change the number After adjusting the date press ENTER and move the with the DOWN key to the time Adjust in the same manner SET OK will flash Press ESC to return to the previous menu screen Note The calendar is backed up by a battery on the printed circuit board Confirm the time if the unit has not been powered for several weeks 10 CONFIGURATION Now that the general method of key display is known the remaining functions can be easily performed Refer to the Appendix for a table of KEY D
20. CONFIGURATION 33 Sensor View 1 4 This first screen Sensor View 1 4 shows S1 1 53652 23 75 temperature compensated conductivity and S2 7 39979 23 35 Ge S3 091 23 73 o readings for S1 and S2 resistivity Press Next 4 is a ed a Press Next The second screen shows raw S2 5 75341 values not temperature compensated of S3 0 93 conductivity and resistivity Press Next 4 SENORA Press Next The third screen indicates the TOC TOC CURVE o Curve presently in use the TOC reading and TOC 82 32 the difference between S1 and S2 Delta 5 86327 Press Next J Sensor View 4 4 Now D Init D Difference that is NowD 5 86327 converted to TOC Init D 0 00008 PPB set 0000 PPB set Not used In the Sensor View area it is possible to observe measurements in both the non oxidizing mode UV Lamp Off and in the oxidizing mode UV Lamp ON First the unit must be placed in the non measuring Standby mode by pushing the START STOP button which turns off the UV lamp and returns the display to the TITLE screen Once in non measuring Standby mode return to the Sensor View area in SETUP as described above After sufficient time about 2 minutes has been allowed for the UV lamp to stabilize the delta conductivity in the non measuring mode STAND BY can be observed This information would be requested in event of a problem where troubleshooting is required CAUTION PRESSING THE MENUS KEY WHILE IN SENS
21. ISPLAY FUNCTIONS and the Operation Flow Charts SYSTEM NAME Go to 10 System Config 1 on 27 page of main menus by moving the asterisk with the up and down keys until it is on line 10 CALENDAR SETUP SYSTEM CONFIG1 SYSTEM CONFIG 2 MAINTENANCE Press ENTER SYSTEM CONFIG 1 Sys Name 0000 Print T unit min Program Ver x xx Press ENTER to highlight the first digit and using the UP DOWN and NEXT keys the Sys Name may be set at 0000 or it may be an abbreviated form of the serial number For example for S N 960012 the Sys Name would be 9612 This is arbitrary and it can be changed by the user OUTPUT SETUP This section provides instruction for setup of the 550 outputs If you are using this Analyzer for measurement only you may proceed to the AutoStart section of configuration Otherwise configure outputs as described in the sections below ALARM SETUP CODES and SETPOINTS The Thornton 550 has two independent relay alarms Each can be configured for one of the three measurement parameters on the display Choose the parameter and set point The condition NO or NC for each relay is determined by the wiring terminals selected see INSTALLATION Configuring the alarms requires the following procedure There is also a menu tree in Appendix B From the title screen press MENUS Move to 1 ALARM MODE 1 or 2 ALARM MODE 2 Press ENTER to reach the following screen display for either alarm ALARM 1 MODE
22. Menus and select 12 MAINTENANCE using the NEXT and UP DOWN keys Press ENTER and change pass word Factory default is 0000 using the UP key Press ENTER and select 4 Board Calib in MAINTENANCE 2 4 MAINTENANCE 2 4 4 Board Calib 5 Sensor Calib 6 TOC Calib Press ENTER 4 BOARD CALIBRATION S1S2 oR KR TH S3 oR MR C TH OPEN Prs Enter ESC Press ESC to terminate this procedure and return to the Title Screen To proceed disconnect the Sensor 1 and Sensor 2 cables from the board see Figure 1 Figure 1 Printed Circuit Board MQ S3 8 in eu oe raise C7 H OUT S2 After disconnecting S1 and S2 from the board push ENTER resulting in these displays BOARD CALIBRATION BOARD CALIBRATION 1S2 R KR 1S2 Rc KR TH 3 OR MR C OR MR CG TH Calibration Doing R 4K Press Enter Plug one each of Assembly A and B into the connectors of S1 amp S2 see Figure 2 Figure 2 26 CALIBRATION Printed Circuit Board t Mo 83 gt 4kQ eem 100 KQ z N 81 Poe Assembly A and B mmm Cem OUT S2 E After inserting the resistor assemblies as shown above press ENTER to result in these displays BOARD CALIBRATION S1S2 Rc KR TH BOARD CALIBRATION S182 Rc ke THE 3 OR MR C TH R 100K Press Enter
23. ONFIG 2 MAINTENANCE Press ENTER enter the Password Factory default is 0000 using the UP and ENTER keys the first screen MAINTENANCE 1 4 will display Using the DOWN UP keys select Item 11 Other Setup MAINTENANCE 4 4 10 A D View 11 Other Setup Press ENTER Use UP DOWN to toggle to ON Press ENTER 20 OPERATION Using the NEXT key select MEASURE PARA 2 screen fourth screen in Other Setup menu and select Sensor Status using the DOWN key 4 MEASURE PARA2 Change Sensor Status from OXXX to 1XXX RESERVE 0000 by pressing ENTER and UP keys Refer to ADVANCED CONFIGURATION for more information RESERVE 0000 Sensor Status 0000 END MEASUREMENT To terminate measurement at any time press START STOP and the display will return to the TITLE screen OPERATION E CHAPTER 6 MAINTENANCE LAMP REPLACEMENT The only maintenance that is required on a regular basis is replacement of the UV lamp When the lamp usage time has reached 4 000 hours a UV lamp alarm appears on the display At some point after 4 000 hours the UV radiation will gradually degrade and eventually will affect the validity of the measurement WARNING Do not remove back cover with unit ON or Power to the NOOR Wh CO 9 unit ON UV light is harmful to the eyes Stop measuring by pushing the START STOP key Switch power OFF Disconnect the power cord Allow unit to cool 10 minutes before changing the lamp
24. OR VIEW WILL TURN ON THE UV LAMP THIS FUNCION EXISTS AS A MAINTENANCE TOOL AND IS INTENDED FOR USE BY AUTHORIZED THORNTON SERVICE PERSONNEL ONLY TOC CURVE In Sensor View screen 3 4 the display shows the TOC Curve designation used to determine the TOC value measured by the analyzer The factory default for all three models 550 550 HT 550 SX is TOC Curve This curve is designed to provide optimum performance for typical sample waters that meet the water quality and TOC range limits specified for these analyzers In certain circumstances this Factory default may be changed These are special cases where a sample water may contain known levels of specific organics in which 34 ADVANCED CONFIGURATION case a different curve designation may be entered This alteration will require factory support and should only be performed by factory trained and certified personnel ADVANCED CONFIGURATION 35 APPENDIX A KEY DISPLAY FUNCTIONS MAJOR FUNCTION FUNCTION WHEN UNIT IS MEASURING TOC FUNCTION WHEN UNIT IS IN STANDBY FUNCTION WITHIN ITEM 12 MAINTENANCE MENUS START Start or Stop Stop Measuring Start Measuring STOP Measuring TOC TOC TOC ESC Backs out of current Escapes back to menu screen Measurement Mode Push to enter setup amp configuration Menus Scrolls the menu displays or moves the Underline to the next location Saves changes made within menu screens Allows access to or exit from the
25. THORNTON Part No 84428 Leading Pure Water Analytics 550 Total Organic Carbon Analyzer Instruction Manual IMPORTANT SAFETY INFORMATION Please read and observe the following INSTALLATION This instrument must be installed by trained instrumentation personnel in accordance with relevant local codes and instructions in this manual Observe all instrument specifications and ratings SHOCK HAZARD Make sure power to all wires is turned off before proceeding with installation or service of this instrument High voltage may be present on the input power and relay wires RELAY CONTROL ACTION Relays will always de energize on loss of power equivalent to normal state regardless of relay state setting for powered operation Configure any control system using these relays with fail safe logic accordingly PROCESS UPSETS Because process safety conditions may depend on consistent operation of this instrument take appropriate action to maintain conditions during sensor cleaning replacement or sensor or instrument calibration This manual includes safety information with the following designations and formats WARNING POTENTIAL FOR PERSONAL INJURY CAUTION possible instrument damage or malfunction NOTE important operating information SERVICE AND REPAIR INFORMATION This manual provides instruction to properly setup and operate the 550 model TOC Analyzers Tampering with modifying or dis assembly of any internal components
26. alyzer turned off and the power cord disconnected from the power source remove the top cover Depress each of the four buttons on opposite sides just under the lip of the top cover so that each of the 4 strips on top lifts open The exposed large Phillips head screws can now be loosened so that the top cover can be removed Note There is a proper front and back to the cover The bottom sides of the cover have male and female grooves respectively When replacing the cover make sure the female groove on the cover lines up with the male mating surface on the housing on one side the genders will be reversed on the other side The pressure regulator can be seen toward the back left of the analyzer First rotate the flow adjustment knob on the front of the analyzer counterclockwise to the full open position Then on the internal pressure regulator rotate the knob on the top of the regulator to adjust the pressure until the flow reads 100 ml min 6 INSTALLATION SET UP After rinsing use the flow adjustment knob to set the flow to 20 ml min CAUTION Even if no pressure adjustment is required which is the usual case the cover should be removed so that the analyzer can be checked for water leaks as any leak could be a source of error in the readings and also could lead to damage or failure of the unit When all of these installation steps have been completed replace the top cover plug in the power cord and press the power butto
27. ation is performed by the System Check routine each time the START button is pushed to start measuring This is explained in ADVANCED CONFIGURATION However the system can be configured to automatically zero calibrate at set time intervals by use of the first digit from the left in RESERVE2 of MEASURE PARA2 shown above 14 CONFIGURATION Reserve2 Period of Auto Zero OXXX No Auto Zero 1XXX 20 hours 2XXX 40 hours 3XXX 60 hours 4XXX 80 hours 5XXX 100 hours 6XXX 200 hours 7XXX 1000 hours After changing this parameter press Save to write it to memory then switch the power OFF then ON Note the following 1 The second digit of RESERVE2 is used to configure the communication port The third digit is used for special functions only and is normally zero Its function is explained in ADVANCED CONFIGURATION RESERVES is not used and is normally set to 1000 Sensor Status is normally 0000 It is changed only in certain operating situations as explained in ADVANCED CONFIGURATION For any application outside the normal operating parameters please consult Mettler Toledo Thornton Inc technical support department PRINTOUT OF CONFIGURATION DATABASE A printer attached to the printer port can be used to print out the configuration database This is advisable for documentation and helpful for troubleshooting To print out the configuration database 1 2 STOP measuring by pressing the START STOP button Push Menus and
28. could be the result of the operator switching the power ON or from restoration of power after an outage It is recommended that this be left OFF for initial operation in a particular application To change the status insure the asterisk is in front of the OFF on the AUTO START line press the ENTER key and use UP DOWN keys to toggle OFF ON Press SAVE to write to memory CONFIGURATION 13 MEASUREMENT DISPLAY The user has the option of displaying the measurement value of the incoming water sample as resistivity conductivity or temperature uncompensated conductivity To change from the default value of resistivity Go to MEASURE PARA 2 choose 12 MAINTENANCE Then move the asterisk to 11 Other Setup After entering Other Setup set Write to ON to edit Other Setup parameters MAINTENANCE 4 4 10 A D View 11 Other Setup Press Enter Other Setup Write ON Press Enter Press Next 3 times to go to 4 MEASURE PARA 2 screen 4 MEASURE PARA 2 RESERVE2 0000 RESERVES 1000 Sensor Status 0000 In the RESERVE2 line the codes for measurement display are set by the fourth digit as follows XXX0 Resistivity MQ cm XXX1 Conductivity uS cm XXX2 Uncompensated Conductivity uS cm The display will indicate MQ cm or uS cm according to the code selected AUTOMATIC ZERO CALIBRATION CONTROL Zero calibration is to account for the small differences in measurement between Sensor 1 S1 and Sensor 2 S2 A zero calibr
29. d Health Administration OSHA to laboratories which have been recognized to perform certification to U S Standards 46 DECLARATION OF CSA COMPLIANCE WARRANTY This Warranty is given expressly and in lieu of all other warranties express or implied The Buyer agrees that there is no warranty of merchantability and that there are no other warranties express or implied which extend beyond the description on the face of this agreement Mettler Toledo Thornton Inc hereinafter referred to as The Company warrants to the original Buyer each electrode component or instrument manufactured and or sold by The Company to be free from defects in material and workmanship in normal use and service for a period of one 1 year from shipment unless expressly stated otherwise by the product packaging or expressly agreed to in advance by the Company The obligation of The Company under this warranty is limited to repair or replacement of the defective product at The Company s discretion All warranty claims shall be returned to The Company pursuant to The Company s Returned Goods Authorization program Shipping costs including return shipping are the responsibility of The Buyer The Company assumes no responsibility for any direct or indirect costs associated with removal of defective products or re installation of replacement products The Company shall not be responsible for damage to any electrode component or instrument resulting from misuse
30. d calibration follows in the next section The required resistor set Part No 139 005 is available from Mettler Toledo Thornton The resistivity temperature sensor verification calibration which is performed after the board level calibration can be best obtained using the values from a recently calibrated resistivity monitor and sensor such as the Thornton 770MAX system The measuring point of the 770MAX should be close to the connection point for the Thornton 550 TOC verification calibration can be performed a number of ways One method of verification is to install a calibrated 550 TOC analyzer in parallel with the test unit The results of TOC Resistivity and Temperature are compared over a period of time If the results from the test unit compare favorably with the calibrated 550 TOC unit within published operating tolerances the test unit calibration is verified A second more extensive TOC calibration subjects the test unit to a known TOC level A sample is prepared by adding some suitable reagent into low TOC water to prepare a sample with known TOC level CALIBRATION 29 Run the calibration sample through the unit until stable readings are achieved The instrument value can be adjusted in the following manner In the second screen of MAINTENANCE Mode select 6 TOC Calib MAINTENANCE 2 4 4 Board Calib 5 Sensor Calib 6 TOC Calib Press ENTER TOC Calibration T 2 85 gt 2 85 R 18 10 gt 18 10 T F 1
31. eaningless number until the output as measured with a current meter reads 4 mA At HOLD 100 do likewise for the 20 mA output value For calibrating a 4 20 mA analog receiver loop such as one with a pen recorder the additional intermediate HOLD values of 25 8 mA 50 12 mA and 75 16 mA can be employed Adjust the receiver instrument indication to conform to these output values After completion of the loop calibration Press ESC and go to 6 ANALOG SETUP and change the Output code from hold 24 CALIBRATION AUTO ZERO CALIBRATION TOC measurement depends upon the difference in conductivity readings between Sensor 1 and Sensor 2 As with any electronic measurement device the zero may drift slightly over a period of time In order to maintain a high accuracy measurement these two sensors should be auto balanced This routine is actually initiated every time the START STOP key is pressed to start the measurement This is indicated on the display screen as System Check Also the instrument can be configured to initiate this routine at specified time intervals This is achieved by setting the first digit from the left in RESERVE2 of MEASURE PARA2 See APPENDIX A for location of MEASURE PARA2 and AUTOMATIC ZERO CALIBRATION CONTROL for a table of Period of Auto Zero This Auto Zero Calibration is important for measurement in high purity water However if the resistivity of the water is 10 MQ cm or lower Auto Zero Calibration
32. fferential conductivity This difference in conductivity is used to determine the amount of organic carbon present Flow Pressure Se UV Oxidation ee Meter Flow Conductivity Conductivity Control Valve Sensor 1 Sensor 2 Control Valve aces D Ce SS v Sample Outlet Resistivity 7 Sensor 3 CPU Se ER Flow Orifice gt y y s e Printer en Ger Ze Optional Display Ouni gt Temperature Sample Outlet Termindl gt Resistivity The sample water enters the analyzer and passes through a pressure regulator which controls sample pressure to downstream components Here the sample splits into two flow paths where a portion of the flow is directed to the by pass streamline where resistivity conductivity and temperature are measured via Sensor 3 These values are represented on the LCD display The other portion of the sample is directed through a second conductivity sensor 1 measuring the sample conductivity prior to oxidation Next the sample enters the oxidation chamber As the sample moves through the oxidation chamber it is subjected to high intensity ultraviolet radiation at 185 nm effectively oxidizing the sample to CO After oxidation the sample passes through a third conductivity sensor 2 where the conductivity and temperature are measured again to determine the level of Total Organic Carbon TOC The microprocessor of the Thornton 550 TOC Analyzer uses the mea
33. her Setup Write OFF ESC Ke ESC Key y N J USER SETUP NEXT KEY Cell 2 Type R Const 1000 TH Const 1000 NEXT KEY gt NEXT KEY Sensor View 4 4 NowD 0 56854 InitD 0 00008 PPb set 20000 Cell 3 Mohm Type 0000 R Const 1000 TH Const 1000 40 APPENDIX 550 OPERATION CHART Maintenance Mode Other Setup menus Back to Measurement Mode Press ESC key three times Other Setup Menus From previous page Es TOC Carve TOC Curve configuration TOC Curve 201 FLOW Rate 20 Full Oxidation NEXT Initialize Limit Setup For Factory or Service use only 2 INITIALIZE CHANGE Calib No 1 0010 The Calib No 1 amp 2 number is read as 0 010 uS cm Calib No 2 0050 See Table in Chapter 8 Programmed TOC Curve 2 NEXT Measurement Parameter 1 3 MEASURE PARA 1 P O d Molni imito 1830 Designates MQ cm limit value on display RESERVE 1 0000 Reserve not used To change flow rate see CONFIGURATION NEXT Measurement Parameter 2 Multi functional See ADVANCED CONFIGURATION RESERVE 2 0000 RESERVE 3 1000 Not used Sensor Status 0000 For enabling or disabling Error 2 see ADVANCED CONFIGURATION NEXT UV Light Time 5 UV TIME UV ON TIME 0020 ON TIME total hrs present lamp has been on UV CHG TIME 4000 CHG TIME recommended limit for lamp UV TIME CLR OFF TIME CLR Sets On Time to zero NEXT TOC OFFSET 6 TOC OFFSET
34. is not necessary and the first digit of RESERVE2 should be left at 0 If Auto Start has been set to ON the Auto Zero Calibration System Check will commence anytime the unit is switched ON or returns to a powered condition after a power outage Auto Start is found in SYSTEM CONFIG2 See APPENDIX and CONFIGURATION For a further explanation of the Auto Zero Routine refer to ADVANCED CONFIGURATION BOARD CALIBRATION This section describes a procedure to verify the functionality and accuracy of the electronics within the instrument The Thornton 550 TOC Analyzer has two sensors for TOC measurement and one sensor for measurement of the incoming water sample These sensors are connected to the motherboard of the 550 Periodically the motherboard should be calibrated for optimal performance of the sensors This should be done just before a calibration verification A convenient time may be when the UV lamp is changed after 4 000 hours The resistor set used for this calibration is designated Part No 139 005 139 007 for SX models and is available from Mettler Toledo Thornton Inc The set consists of the following assemblies 139 005 Resistor Set 1 each Assembly A 4 KQ 100 KQ 1 each Assembly B 4 KQ 100 KQ 1 each Assembly C Jumper 1 each Assembly D 2 MQ 100 KQ 1 each Assembly E 1000 pF 2MQ 100 KQ CALIBRATION 25 Stop the measurement and remove the top cover CAUTION POWER IS LIVE DURING THIS PROCEDURE Press
35. menu lines and or selected items 1 Selects an item denoted by an 2 Increase a number 1 Selects an item denoted by an 2 Decrease a number Push to enter setup amp configuration Menus Press Once Displays the history Press twice displays alarm set points of a parameter Total UV light time TF and RF Saves changes made within menu screens To read data in Data History To read data in Data History Push to enter setup amp configuration Menus Turns UV lamp on off in sensor view Shows sensor view from sensor calib screen Moves the menu display down move cursor Saves changes made within menu screens Allows access to or exit from the menu lines and or selected items Moves the within the menus or Increases a number Moves the within the menus or Decreases a number Backs out of current menu screen 36 APPENDIX SYSTEM CHECK SEQUENCE Push START key I Wait 3 minutes to stabilize S2 S1 value S1 S2 lt CalibNo 1 See Table in Chap 8 YES Push Start stop Key and Enter Key Simultaneously H Sets S1 S2 0 NO Wait for 1 minute See Table in Chap 8 S1 S2 lt CalibNo 2 Wait for 1 minute APPENDIX NO y SYSTEM CHECK PASS y
36. n at the rear of the analyzer to ON INSTALLATION SET UP 7 CHAPTER 3 CONFIGURATION The unit can be configured before or after installation as described in Chapter 2 When the unit is first powered the following TITLE display will be seen THORNTON 550 TOC Analyzer Ver 1 XX SC Up Start Bb DE air Symbol Name Major function Menus Menu key Enter menu display Save Save key Save changes Start Stop Start measurement Start measuring TOC Stop measurement Stop measuring TOC Up Up key Increase number move the cursor or check mark Down Down key Decrease number move the cursor or check mark Enter Enter key Enter or exit from a menu line Esc Escape key Escape from the current menu level to the previous menu level Next Next key Scroll the menu displays move cursor 8 CONFIGURATION The 550 is available in three different models the standard unit known simply as the 550 will display the title as shown above The High Temperature version will show the model number 550 HT and the enhanced resolution version will display the model number 550 SX The current software version installed is also displayed below the model number This title screen will also display two other status indicators when programmed to do so In the bottom right hand corner the word Demo will flash indicating that the analyzer has been placed into demonstration mode Al
37. nded lamp life of 4 000 hours has AL1 H Uy been exceeded If a malfunction or abnormality occurs an error screen will appear and will alternate with the measurement screen According to the Error Code Table see below ERROR 16 this indicates the temperature at Sensor 3 TMP OVER Incoming Sample is too high OPERATION 19 ERROR CODES Message Fault Cause SYSTEM CHECK Unable to measure TOC Differential between sensors FAILED before UV oxidation is too great ERROR 02 Unable to measure TOC Conductivity of sample water is greater than 20 uS cm ERROR 03 Sensor 1 error Sensor 1 cable not connected or sensor fault ERROR 08 Sensor 2 error Sensor 2 cable not connected or sensor fault ERROR 13 Sensor 3 error Sensor 3 cable not connected or sensor fault ERROR 18 UV lamp life finished Replace UV lamp ERROR 06 Sensor 1 temperature error Temperature Sensor error or ERROR 11 Sensor 2 temperature error temperature above allowable ERROR 16 Sensor 3 temperature error Di ERROR 07 Sensor 1 temperature error Temperature Sensor error or ERROR 12 Sensor 2 temperature error temperature below allowable ERROR 17 Sensor 3 temperature error menue Error 02 which prevents measurement can be overridden using the Sensor Status function in MEASURE PARA 2 SEE CHAPTER 8 ADVANCED CONFIGURATION Press SETUP and select item 12 MAINTENANCE by pressing the NEXT and DOWN keys CALENDER SETUP SYSTEM CONFIG 1 SYSTEM C
38. negligence accident or resulting from repairs alterations or installations made by any person or firm not duly authorized by The Company No agent is authorized to assume for The Company any liability except as above set forth The Company warrants that services will be performed in a workmanlike manner in conformity with standard industry practice Should any nonconformity be detected within 30 days after the work is completed and prompt notification is made by Buyer in writing to the Company Company will supply the necessary service direction or consultation to correct the nonconformity Returned Goods Policy A Returned Material Authorization RMA number must accompany all returned goods This authorization is obtained by calling our Technical Service 800 510 7873 or 781 301 8600 All transportation costs on authorized returns must be prepaid Authorized replacement parts sent prior to receipt and evaluation of merchandise being returned will be invoiced in full Credit will be issued only after the returned part is received and evaluated by factory personnel The Company is not responsible for products returned without proper authorization Factory Restocking Charge Items returned to The Company more than 30 days after shipment will be subject to a 25 restocking charge plus any additional charges for refurbishment to salable condition The Company will not accept returns more than 90 days after shipment unless returned under warranty o
39. nt is updated every 2 seconds TMP 25 6 C Trend data can be viewed by pushing NEXT ESC returns to the Measurement Display TOC RES 75 2 18 2 Time interval is determined by Print Setup 100 2 17 6 See PRINT SETUP 200 6 17 2 OPERATION 47 From the above screen the Measurement Trend Check Mode can be accessed with ENTER The past record of measurement values can be accessed with UP DOWN Pressing ENTER again will show the three most current readings on the display TIME TOC RES 255 Lines of data are stored The values are 10 30 75 2 18 2 the instantaneous measurement at the time 11 00 100 2 17 6 shown not an average value 11 30 200 6 17 2 ESC will return the display to the regular Measurement screen TREND DATA CLEAR If the unit has been moved and a new sample is being introduced or it is otherwise desirable the trend data can be erased First stop measurement with the START STOP button Press Menus key and then access TREND CLEAR in 11 System Config2 using the NEXT and DOWN keys 9 CALENDAR SETUP 10 SYSTEM CONFIG 1 11 SYSTEM CONFIG 2 12 MAINTENANCE Press ENTER key SYSTEM CONFIG 2 Auto Start Print SYS Conf History Clear Select History Clear using the DOWN key and press ENTER Toggle to ON using UP DOWN keys and press ENTER The trend data will be cleared PRINT TREND DATA If a printer is connected to the printer port the measurement trend data can be printed Push Menus
40. of this analyzer beyond that which is explicitly spelled out in this manual is prohibited and will render the manufacturers warranty null and void TABLE OF CONTENTS CHAPTER 1 GETTING STARTE 1 INTRODUCTION sect ack eins outed cure ee 1 PRINCIPLE OF EE EIERE Ee 2 CHAPTER 2 INSTALLATION SET UP scssssssssossssssessseesssessssessscessseessueesseersnessseessees 4 Beet ee 4 EMECTRICAL CONNECTIONS eeEee EE 4 SAMPLE TUBING CONNECTIONS sasana a R 4 EISE 5 BUA RNS EE 5 USER INTEREACEIPRINTER tter rrr nrn 5 STA EE Ee Ee 6 CHAPTER 3 CONEIGURATION EE 8 USER SETUP AND CONFIGURATION MENUS s susiiiinsseesssseniiiiiirnneeeserrrnnn 9 EEE A a a S a 10 SENT eebe aerer 11 SEa 11 ALARM SETUP CODES and SETPOINTS cscccsssssssesessessssesssseessesessvsssseseseenseees 11 ALARM X 1 OR 2 MODE CONEIGURATION 12 Pi Ne UP Ee 12 ANALOG 4 20 MA OUTPUT EE 13 GTO TEE EE 13 MEASUREMENT DIS e 14 AUTOMATIC ZERO CALIBRATION CONTROL aaasssssssnnniiiiiinneeerrirrririnrnnrn 14 PRINTOUT OF CONFIGURATION DATABASE iinnissessssrniiiiiirirrseeeererrrnnnn 15 CHAPTER 4 DEMONSTRATION MODE E 16 CHAPTER 5 OPERATION EE 17 DOVE ON EE 17 BEFORE MEASURING ee 17 IS 17 EENEG eege deg 18 PRINT TREND DATA eelere 18 ALARM SETPOINT SE BEEN teuer 19 ACARM INDICA TON eae eee ae bees eee yeaa E EE 19 EREECHEN 20 ENDCOMESEEIEEMERTE dee 21 CHAPTER 6 MAINTENANCE EE 22 LAMP REPLACEMENT eegener ege Eiee 22 CHAPTER 7 CALUIBRATION
41. passing indicates there is a problem and the screen will display SYSTEM CHECK FAILED If this occurs turn the unit off then on again and push the START button to once again initiate the System Check sequence If the System Check again fails the System Check FAILED can be overridden by changing the RESERVE2 in the MEASURE PARA 2 4th screen in OTHER SETUP menus as follows 4 MEASURE PARA 2 RESERVE2 0000 RESERVE3 1000 Sensor Status 0000 Select RESERVE2 using UP DOWN key and press ENTER Change from XX0X Normal System Check to XX1X Special System Check using the NEXT and UP keys This will override SYSTEM CHECK FAILED and permit the sequence to advance to the next stage turn on UV lamp This means that the difference between the zero readings of S1 and S2 will not be eliminated and there may be some error in the measured TOC value This error is usually insignificant in lower quality water lt 10 MQ cm VIEWING SENSORS To view the readings of the individual sensors press Menus and select 12 MAINTENANCE using the NEXT and UP DOWN keys 9 CALENDER SETUP 10 SYSTEM CONFIG1 11 SYSTEM CONFIG2 12 MAINTENANCE Press ENTER enter the Password Factory default is 0000 using the UP and ENTER keys the first screen MAINTENANCE 1 4 will display Using the DOWN UP keys select Item 2 Sensor View and press ENTER MAINTENANCE 1 4 1 Demo Mode On Off 2 Sensor View 3 EEPROM Setup ADVANCED
42. r for non warranty repair Special Products Cancellation or return of special products will not be accepted Disclaimer of Damages In no event shall The Company be liable for any type of special consequential incidental or penal damages whether such damages arise out of or are a result of breach of contract warranty tort including negligence strict liability or otherwise Such damages shall include but not be limited to loss of profits or revenues loss of use of the equipment or associated equipment cost of substitute equipment facilities down time costs increased construction costs or claims of The Buyer s customers or contractors for such damages The Buyer agrees that in the event of a transfer assignment or lease of the equipment sold hereunder The Buyer shall secure for The Company the protection afforded to it in this paragraph WARRANTY 47 Mettler Toledo Thornton Inc 36 Middlesex Turnpike Bedford MA 01730 Tel 1 781 301 8600 Fax 1 781 301 8701 Toll Free 1 800 510 PURE thornton info mt com Part 84428 Rev B 02 08 Www mt com thornton
43. required measurement parameter for process certification and performance verification It is evident that a fast response easy to operate and maintain device has recognizable benefits for the user The Thornton 550 Total Organic Carbon Analyzer provides a faster and easier method of on line measurement As its predecessor the 502P the 550 TOC analyzer units offers the widest dynamic water quality range that can be measured without Cumbersome reagents or accessories And it is the only known TOC Analyzer to measure on line continuously The 550 TOC Analyzer is an online device that can be used in a permanent installation and also as a portable device TOC measurement is capable throughout a range of 0 1 to 1000 ppb for the standard and high temperature models 0 05 to 30 ppb for the SX model The Mettler Toledo Thornton Inc factory provides in house calibrations and testing services and also offers Field Service support consult local factory sales representatives for details The Specifications Principal of Operation Installation Configuration Operation Maintenance and Calibration of this unique high quality analyzer follow If you have any questions or comments about this manual or the analyzer itself please do not hesitate to contact us United States Patent No 5 518 608 issued GETTING STARTED 1 PRINCIPLE OF OPERATION The Thornton 550 TOC Analyzer measures Total Organic Carbon in pure and ultrapure water based on di
44. rk as shown below with the adjacent indicators C and US and a Certificate of Compliance from the Canadian Standards Association has been issued and is on file SR PRODUCTS CLASS 2252 03 PROCESS CONTROL EQUIPMENT CLASS 2252 83 PROCESS CONTROL EQUIPMENT Certificate to U S Standards Listed below is the detailed information noted on this certificate APPLICABLE REQUIREMENTS CSA Standard C22 2 No 0 M92 General Requirements Canadian Electrical Code Part II 0 4 M1982 Bonding and Grounding of Electrical Equipment Protective Grounding 1010 1 92 Safety Requirements of Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements Includes Amendment 1 1010 1B 97 Amendment 2 to CAN CSA C22 2 No 1010 1 92 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements ANSI ISA 82 01 1994 Safety Standards Electrical and Electronic Test Measuring Controlling and Related Equipment General Requirements TIL I 29A Process Control equipment The C and US indicators adjacent to the CSA Mark signify that the product has been evaluated to the applicable CSA and ANSI UL standards for use in Canada and the U S gt respectively This US indicator includes products eligible to bear the NRTL indicator i e National Recognized Testing Laboratory is a designation granted by the U S Occupational Safety an
45. ry 39 550 OPERATION CHART Setup Mode Maintenance menus Back to Measurement Mode or Title Screen Press ESC key twice aaauasauasaiaasssasssssssssssss MAINTENANCE MODE To MAIN MENUS SCREEN From MAIN MENU SCREEN 3 3 NEXT KEY Sensor View 2 4 S1 1 49524 S2 1 46909 S3 0 93 NEXT KEY NEXT KEY Sensor View 3 4 TOC CURVE 1 TOC 82 32 Delta 5 86352 Playing Demo Password Input DEMO Mark OFF Password Input Password 0000 E J 0000 is Factory Default Sensor View 1 4 A S1 1 53652 23 75 S2 1 50887 23 35 S3 0 91 23 73 MAINTENANCE 1 4 Ne zz 1 Demo Mode On Off 2 Sensor View ra 3 EEPROM Reset EEPRON Reset N EEPROM Write ON Sure ENTER KEY If do Press Enter key Ne i BOARD CALIBRATION D SIS2 OR KR TH S3 OR MR C TH OPEN Prs Enter ESC BE N MAINTENANCE 2 4 Cell 1 IN Type 0000 4 Board Calib R Const 1000 5 Sensor Calib TH Const 1000 6 TOC Calib toc Calibration R T 2 855 2 85 i R 18 104 18 10 T F 1 000 R F 1 000 I Menus Key Lock Out SN Menus Key Lock Out Lock Out OFF MAINTENANCE 3 4 Ke e 7 Lock Out 8 Pass Word Change a 3 9 LCD Contrast Pass word Changes New Pass word 0000 e a 3 LCD Contrast Contrast 1000 g A A D Converter Level 1 1 16 MAINTENANCE 4 4 1 23146 10 A D View NX E 11 Other Setup Ca N Ot
46. s step will be repeated a third time If the System Check is still not OK the system adopts Calib No 2 SEE TABLE ON NEXT PAGE as the acceptable criterion It will check up to five times with 20 seconds between attempts Note These two calibration values can be seen in the 2 screen of the Other Setup menus Press Menus and select item 12 MAINTENANCE by pressing the NEXT and DOWN keys CALENDAR SETUP SYSTEM CONFIG 1 SYSTEM CONFIG 2 MAINTENANCE Press ENTER then enter the Password Factory default is 0000 using the UP and ENTER keys the first screen MAINTENANCE 1 4 will display Use the NEXT button to reach the fourth Maintenance Screen 4 4 Using the DOWN UP keys select Item 11 Other Setup MAINTENANCE 4 4 10 A D View 11 Other Setup Press ENTER The Other Setup WRITE OFF ON screen will appear on the display ADVANCED CONFIGURATION 31 OTHER SETUP WRITE OFF NOTE Changing the WRITE OFF to ON will allow changes to be the factory settings within the OTHER SETUP menu screens This should only be turned to ON if changes are being made Using the NEXT key select INITIALIZE CHANGE screen 2 INITIALIZE CHANGE Calib No 1 0010 Calib No 2 0050 The Table below shows the Calib Numbers for each 550 model Values are in units of uS cm these values are factory set and should not be altered as instrument performance may be affected 550 550 HT 550 SX Calib No 1
47. so it may flash Auto Start ON when the analyzer has been programmed to do so As shown above the front panel of the 550 provides 8 eight keys for manipulation of the unit s set up configuration and maintenance menus See KEYPAD DISPLAY FUNCTIONS Table in the APPENDIX for a detailed description of the function of each key USER SETUP AND CONFIGURATION MENUS When the unit is in Standby mode the first level of menu displays can be accessed by pushing the MENUS key This array of menus will be used to setup or change the configuration of the 550 TOC Analyzer for normal operation The 550 software contains a lockout function that when enabled allows configuration changes only if a password is entered The screens should appear as follows NOTE If lockout is enabled Lockout ON when pushing the MENUS key from the Title Screen the next screen will ask for Password Input The factory default for this password is 0000 all zeros The password can be configured for a personalized four digit password from the Maintenance Menus Otherwise pushing the Menus key from the Title screen will display the main menus THORNTON 550 TOC ANALYZER Ver 1 XX Push MENUS key to enter the password screen as shown below PASS WORD INPUT PASS WORD 0000 Lock Out ON Push ENTER Key to view the 1 page of the main menus as shown here 1 ALARM 1 MODE 2 ALARM 2 MODE 3 ALARM VALUE 4 ALARM DELAY CONFIGUR
48. ss ESC three times to return to TITLE screen e Press START to resume measurement MAINTENANCE 23 CHAPTER 7 CALIBRATION Four aspects of Calibration are covered in this section e Analog Output Calibration This procedure is used to calibrate the analog output loop e Auto Zero Calibration This is a procedure performed by the monitor itself to obtain zero readings of the two TOC sensors and correct for any zero drift e Measurement Verification Calibration These are methods for verifying that the current calibration is valid or to adjust factors for re calibration e Sensor Board Calibration This procedure calibrates the main PC board with a set of resistors and it ensures that the electronics measure resistivity accurately ANALOG OUTPUT CALIBRATION The analog output loop can be calibrated as follows From the title screen press the Menus key Go to 6 ANALOG SETUP Press Enter ANALOG SETUP Output hold 4mALmt 000 0 20mA Lmt 500 0 Press ENTER and set the output to hold by using the UP key Press ENTER It is not necessary to push SAVE as this is a temporary condition only and should not be written on the EEPROM Press ESC to exit back to the menu options and with Down select 7 ANALOG CALIB Press ENTER ANALOG CALIB 4mA LOW 1000 20mAHI 1000 HOLD 00 Since this is a digital device only 2 points are necessary to calibrate the 4 20 mA output At HOLD 00 adjust the 4 mA LOW otherwise m
49. sured values of initial 1 and final 2 conductivity and temperature to determine the change in compensated conductivity which is related to the concentration of organic impurity in the incoming water stream The measurement and sample flow are continuous therefore measurement update time is minimized providing rapid response to any system disturbances The oxidized sample stream passes through a flow meter which has a fine flow control adjustment and then through the OXIDIZED SAMPLE OUTLET port This effluent may be sent to waste or recycled The operating flow rate is typically 20 ml min resulting in residence time in the oxidation chamber of less then one minute The conductivity 2 GETTING STARTED measurements are continuous therefore response time is directly related to the residence time of the sample in the oxidation chamber Values of TOC resistivity or alternatively conductivity or uncompensated conductivity and temperature are displayed on the LCD screen of the instrument These values can also be printed or sent to a computer through RS 232 serial interface ports on the back panel of the instrument at a user selectable time interval The last 255 sets of values are stored in memory at the same time interval for viewing on the screen or a designated number of these data lines can be printed on a demand basis Other outputs include a continuous 4 20mA self powered analog output signal and two configurable potential free
50. the following displays BOARDR CALIBRATION BOARD CALIBRATION 1S2 Re KRc THe S182 Re KRe THe S3 Re Mc C TH ki S3 R Mc Cc THv Calibration Doing R 100K Press Enter Press ENTER again for the following displays 28 CALIBRATION BOARD CALIBRATION S182 Re KRe BOARD CALIBRATION 1S2 Rc ke THe 3 Re Mc Ce THe Calib END Press SAVE 3 Re Mc Ce Calibration Doing Press SAVE Toggle to YES Press ENTER THORNTON Press ESC Twice 550 TOC Analyzer cb Ver x xx Remove Assembly E Push the sensor connectors back into the plugs on the board Replace top cover Push START to resume measurement MEASUREMENT VERIFICATION CALIBRATION Periodically the performance of the Analyzer should be verified It is recommended that factory trained and qualified personnel perform these services Typically calibrations are performed at the Factory however on site service may also be provided in some cases consult the Thornton Technical Services for details Typically the verification procedure is performed at the time of the UV lamp replacement Refer to MAINTENANCE for the procedure for lamp replacement Before performing the TOC Verification Calibration it is advisable to do a board level calibration followed by a resistivity temperature sensor verification calibration The board level calibration procedure uses resistor sets which are plugged into the sensor sockets on the main board The procedure for boar
51. ud 1 stop bit no parity 8 bit data Software such as HyperTerminal a standard Windows based software may be utilized to collect data with a PC START UP After all the tubing has been connected sample water can flow through the unit Open the user furnished sample isolation valve Observe the flow rate from the flow meter on the front panel of the Thornton 550 TOC Analyzer Adjust the flow rate to the maximum setting by means of the flow adjustment knob located at the top of the flow meter If not already installed connect the power cord to the socket located at the rear of the Thornton 550 TOC analyzer and insure the other end is connected to a suitable power source Press the power button located at the rear of the analyzer to ON This will enable the front display screen showing the Thornton name model and software version of the analyzer At this time the analyzer should be rinsing with sample water to remove any impurity present on the sensors or in the system tubing and components This will also help remove air bubbles as any entrained air can cause errors in readings Upon initial installation and start up it is recommended that the analyzer be rinsed for a minimum of 4 hours to 12 hours The analyzer can be used immediately but depending on water quality time may be needed for readings to stabilize If the desired flow rate is not achievable the internal pressure regulator may have to be adjusted With the power to the An
52. yzer PRINTER The connection labeled PRINTER is a 9 pin male or female sub D connection for connecting an optional printer with serial interface The printer port can also be connected to a computer having a serial interface Communication specifications for this port 9600 baud 1 stop bit no parity 8 bit data Software such as hyperterminal a standard windows based software may be utilized to collect data with a PC Mettler Toledo Thornton Inc supplies a small format thermal printer as an optional accessory A straight through 9 pin male or female sub D cable is provided with this printer Configuration Dip switch settings for this optional printer can be found in the APPENDIX An operation manual is also included with the printer Power for this printer is supplied by the 550 TOC ANALYZER 6 VDC The power connection is made at the rear of the analyzer INSTALLATION SET UP 5 RS232C The connection labeled RS232C is also a 9 pin sub D connection for connecting a computer using a serial interface This port used in conjunction with a computer having serial interface capability can be used as an alternate means to collect the operating data from the analyzer The Computer must have the means to collect this serial data which will be transmitted in the same format as it is transmitted to the optional printer The following communication specifications apply Communication specifications for this port 2400 ba
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