Operation Manual 6000TOCi Sensor.pdf

Operation Manual 6000TOCi Sensor6000TOCi Sensor 30 473 834 Rev B6000TOCi Sensor 3 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev BOperation Manual 6000TOCi SensorMETTLER TOLEDO Thornton,Inc.2018No part of this manual may be reproduced or transmitted in any form or by any means,electronic or mechanical,including photocopying(other than where specifically noted),for any purpose without the express written permission of METTLER TOLEDO,Inc.U.S.Government Restricted Rights:This documentation is furnished with Restricted Rights.METTLER TOLEDO THORNTON RESERVES THE RIGHT TO MAKE REFINEMENTS OR CHANGES WITHOUT NOTICE.This document contains proprietary information,which is protected by copyright.All rights are reserved.No part of this document may be photocopied(other than where specifically noted),reproduced or translated,into another language without the prior written consent of METTLER TOLEDO Thornton,Inc.6000TOCi Sensor 4 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev B6000TOCi Sensor 5 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev BContent1 Introduction _ 72 Safety instructions_ 82.1Definitionofequipmentanddocumentationsymbolsanddesignations _ 82.2 Correct disposal of the unit _ 93 6000TOCi Sensor Overview _103.1 High Pressure Applications _113.2 Potential Condensation Applications _113.3 High Temperature Applications _114 6000TOCi Installation Instructions_124.1 Unpacking and inspection of the 6000TOCi _124.2 Installation of the 6000TOCi _124.3 Sample Tubing Connections _144.4 Sample Conditioning Coil _154.5 AC Power Connection _164.6 Sensor Connection _175 6000TOCi Sensor Operation _185.1 Initial Startup _185.2 Initiate Sample Flow _185.3 6000TOCi Guided Setup _185.4 Normal Operation _185.5 Calibration _185.5.1 TOC Calibration Methods _195.5.2 Enter Calibration Mode _195.6 System Suitability Testing _1966000TOCiandM800Configuration _206.1 Channel Setup _206.2 Parameter Setting _216.3 ISM Setup _236.4 ISM/Sensor Alarm _246.5 Printer Setup _246.6 Data Log Setup _256.7 Reset _266.8 ISM Diagnostics _266.9 Calibration Data _276.10 SST Information _286.11 TOC Maintenance _287 6000TOCi Sensor Service Requirements _297.1 UV Lamp Replacement _297.2 Front Panel Cleaning _307.3 Technical Support _307.4 High Capacity Inlet Filter Replacement _317.5 Draining and Shipping Instructions _318Troubleshootingthe6000TOCiSensor _328.1 Basic Troubleshooting _328.2 Fault and Error Messages _329 Accessories and Spare Parts _349.1 M800 Transmitter _349.2 6000TOCi Sensor Accessories and Spare Parts _349.3 6000TOCi Sensor Consumable Items _3410 6000TOCiSensorDefaultSettings_3511 6000TOCiSpecifications _3612 Certificate _3713 Warranty _386000TOCi Sensor 6 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev B6000TOCi Sensor 7 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev B1 IntroductionStatement of intended use The 6000TOCi sensor is a Total Organic Carbon sensor with ISM capabilities,designed to measure the concentration of organic substances in pure and ultra pure water applications.The 6000TOCi is a continuous-flowing,continuous-measurement instrument allowing detection of any TOC change regardless of the duration.The continuous design also allows rapid detection,with changes being recognized 60 seconds from the time the sample enters the sensor.The M800 Transmitter,is a multiparameter,multi-channel instrument with a large,color touch-screen display which conveys measurement and setup information for the 6000TOCi sensor.The M800 is capable of controlling and monitoring the operation of up to four 6000TOCi sensors.When used in combination,the 6000TOCi sensor and M800 transmitter form a TOC measurement system which provides the design flexibility for full integration into water systems.The separate components allow for close positioning of the sensor to the sample point for fastest response,while allowing integration of the transmitter into the local control system.This manual applies to the 6000TOCi sensor family,listed below.For more information on the features of the M800 Transmitter,please refer to the M800 Operating Manual.6000TOCi Sensor FamilyDesignationOrderno.6000TOCi Sensor,100-240VAC,50-60 Hz 30 472 1506000TOCi Sensor,Low ppb calibration,100-240VAC,50-60 Hz 30 472 151The screen images in this manual are intended for general explanation,and can differ from the real display in your transmitter.6000TOCi Sensor 8 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev B2 Safety instructionsThis manual includes safety information with the following designations and formats.2.1 Definitionofequipmentanddocumentationsymbolsanddesignations WARNING:RISK OF ELECTRICAL SHOCK.a CAUTION:possible instrument damage or malfunction.h NOTE:Important operating information.On the instrument indicates:There is alternating current present.The following is a list of general safety instructions and warnings.Failure to adhere to these instructionscanresultindamagetotheequipmentand/orpersonalinjurytotheoperator.The 6000TOCi Sensor should be installed and operated only by personnel familiar with the sensorandwhoarequalifiedforsuchwork.The 6000TOCi Sensor must only be operated under the specified operating conditions.Repair of the 6000TOCi Sensor must be performed by authorized,trained personnel only.Ifthisequipmentisusedinamannernotspecifiedbythemanufacturer,theprotectionprovidedbytheequipmentagainsthazardsmaybeimpaired.Use only factory documented components for repair.METTLER TOLEDO accepts no responsibility for damage caused by unauthorized modifications to the sensor.Follow all warnings,cautions,and instructions indicated on and supplied with this product.Protectivecoversmustbeinplaceunlessqualifiedpersonnelareperformingmaintenance.Installequipmentasspecifiedinthisinstructionmanual.Followappropriatelocalandnational codes.Protective covers must be in place at all times during normal operation.Prior to shipping sensor back to the factory for repair or re-calibration,water MUST be drained from sensor to avoid damage due to freezing.6000TOCi Sensor 9 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev BWARNINGS:Installationofcableconnectionsandservicingofthisproductrequireaccesstoshockhazardvoltagelevels.SwitchorcircuitbreakershallbeincloseproximitytotheequipmentandwithineasyreachoftheOPERATOR;itshallbemarkedasthedisconnectingdevicefortheequipment.Main power must employ a switch or circuit breaker as the disconnecting device for the equipment.ElectricalinstallationmustbeinaccordancewiththeNationalElectricCodeand/oranyotherapplicablenationalorlocalcodes.Safetyandperformancerequirethatthisinstrumentbe connected and properly grounded through a three-wire power source.Ozone gas(O3)is generated inside the 6000TOCi Sensor enclosure during normal operation.The smell of ozone may be apparent when opening the front cover of the enclosure and caution should be taken when opening.Prolonged exposure to ozone gas is hazardous and may cause health problems.NOTE!PROCESS UPSETS:Because process and safety conditions may depend on consistent operation of this sensor,provide appropriate means to maintain operation during sensor maintenance with a replacement TOC sensor.2.2 Correct disposal of the unit When the sensor is finally removed from service,observe all local environmental regulations for proper disposal.Please note the UV lamp supplied with the 6000TOCi contains mercury.Environmental protection Waste electrical products should not be disposed of with household waste.Please recycle where facilities exist.Check with your Local Authority or retailer for recycling advice.h6000TOCi Sensor 10 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev B3 6000TOCi Sensor OverviewThe 6000TOCi Sensor is a Total Organic Carbon sensor designed for use with the M800 transmitter.The M800 will automatically identify the 6000TOCi Sensor when it is connected,and all factory calibration data is automatically read and used for operation and indication.The 6000TOCi Sensor and M800 transmitter are configured with factory default settings to minimize measurement setup time.These default settings allow for sensor operation with minimal configuration atsystemstartup.The6000TOCiSensormayrequireadditionalconfigurationdependantupontheoperational setup.Once these parameters are set,the TOC sensor will function automatically,and willrequireuserinterfaceonlyforperiodicserviceandmaintenance.Measurementsavailablefromthe 6000TOCi Sensor include TOC,Conductivity/Resistivity(compensated and uncompensated),Temperature,Average TOC,Peak TOC,Minimum TOC,and TOC Rate of Change.The 6000TOCi Sensor is designed with four local LED indicators and a UV Lamp control key on the front panel,as shown in the illustration below.The LEDs are designed to provide local indication of sensor status.The operation of the LEDs is synchronized with the M800 fault and error status messages and indications.FunctionColorOperationFaultRedFlashes during Fault condition,sensor operation stoppedErrorAmberIlluminates during Error condition,sensor remains operationalSensor StatusGreenIlluminates whenever AC Power is on and the 6000TOCi is connected to an operating M800UV Lamp OnGreenIlluminates whenever the UV Lamp is onThe UV Lamp control key is designed to provide a local On/Off control for the UV lamp to allow for quicklampreplacementandtoassisttheoperatorduringtroubleshooting,ifnecessary.NOTE:Once the UV Lamp Key is pressed to turn the UV Lamp off,the UV Lamp cannot be turned on from the M800,it can only be turned on by pressing the sensor key again.This function is intended to avoid accidental activation during maintenance.The front cover of the sensor is hinged on the left side.Located at the top and bottom right corners of the sensor enclosure are hexagonal socketed door fasteners.The installation kit provided with the sensor includes the special tool needed to loosen these fasteners and open the front door to the enclosure.Periodicaccesswillberequiredtoperformroutineserviceandmaintenance.h6000TOCi Sensor 11 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev B3.1 HighPressureApplicationsFor installations with process pressure above 85 psig(5.9 bar(g),the High Pressure Regulator(P/N58091552)isrequired.RefertoSampleTubingConnectionsforadditionalinformation.Detailed installation instructions are supplied with the High Pressure Regulator.3.2 Potential Condensation Applications Certain ambient and process temperatures may cause condensation to occur inside the 6000TOCi Sensor.The METTLER TOLEDO Thornton Sample Conditioning Coil provided with the sensor installation kit is designed to reduce condensation conditions by allowing the sample temperature to partiallyequalizewiththeambienttemperature.3.3 HighTemperatureApplicationsFor water temperatures from 70C to 100C(158F to 212F),installation of the Sample Condition-ingCoil(included)isrequired.Inhighpressureapplications,theHighPressureRegulator(P/N58091 552)must be installed upstream of the Sample Conditioning Coil.6000TOCi Sensor 12 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev B4 6000TOCi Installation Instructions4.1 Unpackingandinspectionofthe6000TOCiCarefully unpack the 6000TOCi sensor.The box contains the following items:6000TOCi Sensor 6000TOCi Sensor Instruction Manual 6000TOCi Quick Start Guide Certificate of Calibration Installation Kit includes:One-Sample inlet tube-6 foot(2 m)length of PTFE tubing,0.125 inch(3 mm)O.D.One-Safety drain tube-5 foot(1.5 m)length of tubing,0.31 inch(8 mm)O.D.One-Stainless steel outlet tube One-Plastic 30 cc syringeOne-Hex tool,TOC coverOne-High capacity inlet filter assemblyOne-Adapter,0.25 inch(6 mm)O.D.to 0.125 inch(3 mm)O.D.tubing reducerOne-Sample conditioning coilOne-Wall mount plateOne-Hex tool for wall mount plateThree-Hexagonal socketed bolts for wall mount plate(M6 x 8 mm)One-Threaded stainless steel safety drain fittingOne-Wall mount template4.2 Installation of the 6000TOCi12.8325.70.614.511.9302.89.0229.82.2 55.10.8 21.55.7 144.7ALLOW MINIMUM CLEARANCE OF 12.5 in.318 FOR UV LAMP REPLACEMENT5.4137.2ALLOW MINIMUM CLEARANCE OF 6.1 in.155 9.8248.69.3235.36000TOCi Sensor 13 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev BWALL BRACKETCAL/SST MODULE6000TOCi SENSORCLEARANCE FOR REMOVAL OF UV LAMPCLEARANCE FOR PLUMBING CONNECTION OF 6000TOCiCLEARANCE FOR INSTALLATION/REMOVAL OF CAL/SST SERVICE TOOL USED FOR PERIODIC CALIBRATION,VERIFICATION AND VALIDATION12.50 318 8.56 217 1.64 426.10 155 11.92 303 TOC/SST OVERALL WIDTH20.8 529 9.05 230 TOC SENSOR OVERALL HEIGHT6.46 164 CAL/SST MODULE OVERALL HEIGHT30.5 775 1.68 43 2.32 59 3.82 97 4X 0.260 6.600 THRU ALLINSTALL WITH M6 SIZE SCREW13.00 330 Shown on previous page are the case dimensions for the 6000TOCi Sensor.Mount the 6000TOCi Sensor as close to the sample point of your system as possible.Shorter sample tubing length between the sampling point and the 6000TOCi Sensor will provide a faster response time.The 6000TOCi Sensor can also be placed on a bench-top or table.In this type of installation,the black push-to-connect safety drain fitting located at the bottom of the unit must be removed and replaced with the threaded stainless steel safety drain fitting included in the installation kit.Some of the internal components for the sensor are made of fragile materials;therefore precautions shouldbetakentoavoiddamageduetoimproperhandling.The6000TOCiSensorrequiresroutinemaintenance;therefore it is beneficial to mount the sensor in an easily accessible location.6000TOCi Sensor 14 08/2018 METTLER TOLEDO Thornton,Inc.6000TOCi SensorPrinted in USA 30 473 834 Rev B4.3 SampleTubingConnectionsThe installation kit provided with the sensor includes sample tubing consisting of one 5-foot(1.5 m)length of 0.31 inch(8 mm)O.D.safety drain tubing,one stainless steel outlet drain tube,and one 6-foot(2 m)length of PTFE sample inlet tubing is included for the supply.A 0.25 inch(6 mm)O.D.to 0.125 inch(3 mm)O.D.tubing reducer is also included and can be used where applicable.The following items are necessary to ensure the proper installation of the sensor:Sample isolation valve(not provided with sensor).0.125 inch compression tube fitting for sample point(common tube fitting adapters are available from METTLER TOLEDO Thornton;see accessories for details).NOTE:Thesampleisolationvalveisrequiredtoisolatethesensorwhennecessary.Properinstallation guidelines should be followed when installing this valve to reduce the possibility of air entrapment or sediment in the sample line.1.Remove the protective covers from the sample connections on the sensor.2.Attached the open tube end of the PTFE tubing to the sample isolation valve.Cut excess tubing to minimize sample tubing length.Be sure all fitting