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GE Analytical Instruments ©2016

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DLM 68100-09 EN Rev. A

Chapter 8: Maintenance

Figure 83: The High Pressure Valve Seal — Before Removal

Figure 84: The High Pressure Valve Seal — After Removal

N

OTE

:

Recommended maintenance intervals are for typical applications. Particularly harsh
applications, such as pH



2, high levels of insoluble particles, and near-saturated brine

solutions require more frequent maintenance intervals. Contact GE Analytical Instruments
Technical Support or a GEAI Applications Engineer for specific details on your application.

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Summary of Contents for Sievers Innovox

Page 1: ...Analytical Instruments Sievers InnovOx On Line TOC Analyzer IFIRMWARE VERSION 3 07 OR LATER DLM 68100 09 EN Rev A Operation and Maintenance Manual ...

Page 2: ...60 Spine Road T 44 0 161 864 6800 T 8621 38777735 Boulder CO 80301 3687 USA geai europe ge com geai asia ge com T 1 800 255 6964 ServiceUK Instruments ge com TechSupportSG GEAI ge com T 1 303 444 2009 F 1 303 444 9543 www geinstruments com geai ge com techSupport GEAI ge com ...

Page 3: ... DLM 68100 09 EN Rev A Identification Records Analyzer serial number _______________________ This is located on the side of the Analyzer Date of receipt and installation of the Analyzer _______________________ This is the warranty start date ...

Page 4: ...ung 18 Limitazione di rimedi e responsabilità 19 限定責任および救済 19 限定責任および救済 19 赔偿与责任限制 19 Warnings 20 Chapter 1 Introduction 49 Chapter 2 System Description 51 System Specifications 51 Additional System Specifications 53 Operating Specifications 53 Reagent Consumption 54 SCWO Method Compliance 54 System Overview 54 Sample Flow Path 57 Additional System Components 60 System Controller and Electronics 6...

Page 5: ...al Installation Equipment 73 Step 2 Complete the Identification Records 73 Step 3 Select a Location for the Analyzer 73 Mounting Stand Installation 73 Wall Mount Installation 77 Step 4 Connect the Waste Lines 77 Step 5 Fill the Gas Liquid Separator 79 Step 6 Install Input Output Cables and Accessories 79 Installing the 4 20 mA Connection 84 Installing the Remote Start Binary Input Connection 84 In...

Page 6: ... Calibration 107 Two Point Calibration 109 Calibration with More than Two Points 111 Linear Fit Multi Point Calibration 111 Point to Point Multi Point Calibration 112 Auto Dilution 113 Blank Correction 114 Calibration Groups 114 Preparing for Calibration 115 Save System Settings 115 Perform Maintenance Tasks 116 Setting Up NPOC IC TC TOC Calibration 116 Calibrating the Analyzer 118 Editing a Calib...

Page 7: ... Viewing Data On Screen 152 Exporting Data 152 Reviewing Exported Data 155 Setting Up Input and Output I O 156 The I O Tab 156 Connecting the Analyzer to a Network Via Ethernet 156 Configuring the Analyzer s IP Address 156 Configuring a Personal Computer 157 Collecting Historical and Real Time Data 159 To collect real time data w Ethernet connection 159 Using the Ethernet Connection and Modbus 160...

Page 8: ...enance Tasks 178 Periodic Inspections 178 Preparing the Oxidizer Solution 179 Preparing the Persulfate Oxidizing Solution 180 To prepare the oxidizing solution 180 Preparing the Acid 180 Adding the Dilution Water 180 Performing a Flush 180 Cleaning the Analyzer 181 Cleaning the Gas Liquid Separator 181 Cleaning the Sparger 183 Lubricating the Syringe 184 Consumables Replacement 188 Replacing the P...

Page 9: ...NDIR 223 Heater 223 Heater Testing Criteria 224 Liquid Flow Check 225 Gas Leak Checks 226 Analog Output 239 Binary Output 239 Binary Input 240 Pumps 242 Export Diagnostic Data 243 Testing the Sparger 243 Contacting Technical Support 243 Returning the Analyzer to GE Analytical Instruments 244 Appendix A Analyzer Dimension Diagrams 247 Appendix B Acronyms and Definitions 251 Appendix C Importing Ana...

Page 10: ... Table 8 Maximum Dilution Allowed Using Auto Dilution Feature 114 Table 9 Approximate Number of Calibration Repetitions Possible 118 Table 10 Approximate Number of Verification Repetitions Possible 122 Table 11 Vial Port Repetitions Possible 142 Table 12 Analyzer Ranges with Default Reagent Settings 144 Table 13 Data Fields Output 155 Table 14 Consumables Replacement Schedule 178 Table 15 2 Year M...

Page 11: ... Conduit 89 Figure 14 Wastewater Sampler 90 Figure 15 Velocity Method 91 Figure 16 Top Wastewater Sampler Bracket w Plate Adapter 91 Figure 17 Lower Wastewater Sampler Bracket 92 Figure 18 Velocity Method Barb Fittings Identification 92 Figure 19 Velocity Method Installation 93 Figure 20 Velocity Method Adjusting the Sipper Tube Height 93 Figure 21 Velocity Method Failsafe Installation 94 Figure 2...

Page 12: ...nfigure Online Screen 131 Figure 46 Stream 1 Screen 132 Figure 47 Check Standard Setup Screen 135 Figure 48 Check Standard with Setup Buttons Screen 135 Figure 49 Check Standard Setup Screen 137 Figure 50 The Protocol Screen 139 Figure 51 The Grab Setup Screen 140 Figure 52 The Maintenance Tab 147 Figure 53 Configuring a Conversion Factor 147 Figure 54 Configuring the Factor Equation 148 Figure 55...

Page 13: ... Analyzer 190 Figure 82 Replacing the NDIR Filter 193 Figure 83 The High Pressure Valve Seal Before Removal 195 Figure 84 The High Pressure Valve Seal After Removal 195 Figure 85 The Fluidics Side of the Analyzer 211 Figure 86 The Electronics Side of the Analyzer 212 Figure 87 Electronics in the Top of the Analyzer 213 Figure 88 Analyzer Schematic 214 Figure 89 Connections to the Gas Liquid Separa...

Page 14: ...ck 240 Figure 108 Binary Input Check 241 Figure 109 The Pumps Screen 242 Figure 110 Sparger Diagnostics Screen 243 Figure 111 Analyzer Dimensions Front View 247 Figure 112 Analyzer Dimensions Right Side View 248 Figure 113 Analyzer Dimensions Left Side View 249 Figure 114 Microsoft Excel Spreadsheet Screen Text Import Wizard Step 1 256 Figure 115 Microsoft Excel Spreadsheet Program Text Import Wiz...

Page 15: ...M 68100 03 EN Rev A Firmware 3 00 Mechanical Parts Upgrade September 2011 DLM 68100 04 EN Rev A Firmware 3 01 April 2012 DLM 68100 05 EN Rev A Firmware 3 02 January 2013 DLM 68100 06 EN Rev A Firmware 3 02 Consumables Replacement May 2013 Schedule Update DLM 68100 07 EN Rev A Firmware 3 04 and Wastewater Sampler August 2014 DLM 68100 08 EN Rev A Firmware 3 05 October 2015 DLM 68100 09 EN Rev A Fir...

Page 16: ...nual is covered by the following U S patents for the General Electric Company 8 101 417 8 101 418 8 101 419 8 101 420 and 8 114 676 Licenses for the following software libraries can be found at the websites indicated iText http www lowagie com iText jetty http www mortbay org http www mortbay org LICENSE txt jFreeChart http www jfree org jfreechart json http www json org http www crockford com JSO...

Page 17: ...d shall conform to the reasonable standards of technical competency and performance effective at the time of delivery All service interventions are to be reviewed and authorized as correct and complete at the com pletion of the service by a customer representative or designate GE Analytical Instruments warrants these services for 30 days after the au thorization and will correct any qualifying def...

Page 18: ... acom pañan La garantía es únicamente válida para el comprador original El comprador original no puede transferir esta garantía limitada a nin guna otra parte sin el consentimiento expreso por escrito de GE Analytical Instruments GE Analytical Instruments renuncia específicamente a las garantías implícitas de comercialización e idoneidad para un determinado propósito Limites de correction et de fi...

Page 19: ...alcuna responsabilità per la presenza di eventuali errori In nessun caso GE Analytical Instruments sarà responsabile per danni accidentali o consequenziali correlati o derivanti dall utilizzo del manuale e di altro materiale di supporto correlato La garanzia è valida solo per l acquirente originale La presente garanzia limitata non è trasferibile dall acquirente originale a terzi senza l espresso ...

Page 20: ...tilated area Depending on the composition of the sample halogens such as chlorine or bromine or toxic fumes from fluoride cyanide or other toxic salts can be emitted into the Analyzer s waste To protect against inhalation of hazardous fumes add sodium hydroxide lye or sodium carbonate soda ash to the waste container to neutralize acid in the waste Avoid stratification of the waste within the conta...

Page 21: ...operate the Analyzer with the covers off or the door open Warning Any operation requiring access to the inside of the Analyzer including installation of maintenance items could result in injury To avoid potentially dangerous electric shock or burning turn off power and disconnect from the power supply before opening the Analyzer Use caution when touching any electronic components Warning If a moun...

Page 22: ...een may contain mercury and may be considered hazardous material in your local area Dispose of this items in accordance with federal state or local government regulations Warning Always stop analysis before turning off the Analyzer Warning This is a Class A product In a domestic environment this product may cause electromagnetic interference in which case the user may be required to take adequate ...

Page 23: ...uments for return instructions Whenever changing the lithium battery observe the correct polarity Dispose of used batteries according to the manufacturer s instructions and local disposal requirements Warning This symbol on the instrument indicates that the product does not contain any restricted substances included in China RoHS II Warning This equipment must be electrically grounded in accordanc...

Page 24: ... al recipiente de residuos a fin de neutralizar el ácido en los residuos Agite el recipiente de cuando en cuando para evitar que los residuos se estratifiquen dentro del mismo Advertencia Este símbolo indica que para cumplir con la Ley 2002 96 EC de Desecho de Equipamientos Eléctricos y Electrónicos WEEE por su sigla en inglés de la Unión Europea el Analyzer debe desecharse en forma independiente ...

Page 25: ... ir atornillado ya sea a la pared o al piso antes de la instalación del Analyzer Advertencia La presión del gas comprimido en la entrada de gases del Analyzer no debe exceder de 689 kPa 100 psig La presión del gas comprimido en la entrada de resoplado de gases del panel de filtrado no debe exceder de 276 kPa 40 psig Utilice solamente nitrógeno o aire seco libre de aceite Advertencia Si el accesori...

Page 26: ...a el instrumento Advertencia Para conocer las técnicas apropiadas de desecho consulte la hoja de datos de seguridad del material MSDS por su sigla en inglés que se encuentra junto a cada familia de estándares y reactivos Advertencia Mantenga los objetos extraños alejados del ventilador del Analyzer para evitar su ingreso en el dispositivo La entrada del aire de refrigeración del reactor se encuent...

Page 27: ...0 DLM 68100 09 EN Rev A Advertencia El equipo debe tener una conexión eléctrica a tierra de conformidad con los códigos y ordenanzas locales o en ausencia de dichas regulaciones de conformidad con el Código Eléctrico Nacional ANSI NFPA n 70 ...

Page 28: ...outros sais tóxicos podem ser emitidos nos resíduos do analisador Para obter proteção contra a inalação de gases perigosos adicione hidróxido de sódio água sanitária ou carbonato de sódio cinza de soda ao recipiente de resíduos para neutralizar o ácido contido nos resíduos Para evitar a estratificação dos resíduos agite recipiente ocasionalmente Advertência Este símbolo indica que para estar de ac...

Page 29: ...sas desligue e desconecte o Analisador da tomada antes de abri lo Tenha cuidado quando tocar qualquer componente eletrônico Advertência Se uma plataforma de montagem acessória for usada com o Analisador essa deve ser aparafusada na parede ou no chão antes da instalação do Analisador Advertência A pressão do gás comprimido na entrada de gás do Analisador não deve exceder 100 psig 689 kPa A pressão ...

Page 30: ...do de forma não especificada pela GE Analytical Instruments a proteção fornecida pelo instrumento poderá ser prejudicada Advertência Consulte as Especificações de segurança do material que acompanha cada conjunto de modelos e reagentes para identificar as técnicas de descarte apropriadas Advertência Mantenha objetos estranhos afastados do ventilador do Analisador para evitar danificá lo A entrada ...

Page 31: ...e weder Ihre Finger noch ungeeignetes Material in die Ampullenöffnung Warnung Stellen Sie zum Schutz gegen das Einatmen giftiger Dämpfe sicher dass der Analysator an einem gut belüfteten Ort installiert ist Abhängig von der Zusammensetzung der Probe können Halogene wie Chlor oder Brom oder giftige Dämpfe von Fluorid Cyanid oder anderen giftigen Salzen in den Abfall des Analysators abgegeben werden...

Page 32: ... Um Schäden am Analysator und die Gefahr einer Verletzung zu verhindern achten Sie darauf dass der Analysator an eine Steckdose mit der richtigen Spannung angeschlossen wird Warnung Um eine sichere Funktionsweise und einen Schutz vor Verletzungen zu gewährleisten den Analysator nicht ohne Abdeckungen oder bei offener Tür betreiben Warnung Alle Arbeiten im Inneren des Analysators einschließlich der...

Page 33: ...erhalten Warnung Wenn Sie mit Komponenten hantieren die Proben Standardlösungen Abfall oder Reagenzien enthalten tragen Sie einen Augenschutz und Handschuhe Warnung Der Bildschirm kann Quecksilber enthalten und in Ihrem Land als gefährliches Material eingestuft werden Entsorgen Sie diese Teile gemäß Ihrer staatlichen und lokalen Vorschriften Warnung Stoppen Sie die Analyse immer bevor Sie den Anal...

Page 34: ...d oder Gegenstände in diesen Einlass eindringen Warnung Wenn sich Probleme mit der bestückten Leiterplatte PCA ergeben die eine Lithiumbatterie enthält wenden Sie sich bitte wegen der Rücksendeanweisungen an GE Analytical Instruments Beachten Sie bei jedem Wechsel der Lithiumbatterie die richtige Polung Entsorgen Sie die gebrauchten Batterien gemäß den Herstelleranweisungen und den örtlichen Entso...

Page 35: ...ts pour neutraliser les déchets acides Pour éviter la stratification des déchets dans le récipient agitez le périodiquement Avertissement Ce symbole indique qu aux fins de conformité avec la directive 2002 96 CE de l Union Européenne concernant les matériels électroniques et électriques mis au rebut l analyseur doit être jeté séparément des déchets standard Avertissement Des réactifs dangereux per...

Page 36: ... montage doit être boulonné au mur ou au sol avant l installation de l analyseur Avertissement La pression du gaz comprimé à l admission de gaz de l analyseur ne doit pas dépasser 100 psig 689 kPa La pression du gaz comprimé à l admission du gaz de retour sur le panneau filtrant ne doit pas dépasser 40 psig 276 kPa Utiliser uniquement de l air sans huile sec ou de l azote Avertissement Si l access...

Page 37: ...s substances dangereuses fournies avec chaque jeu de standards et avec les réactifs afin d identifier les bonnes techniques de mise au rebut Avertissement Maintenir les corps étrangers à l écart du ventilateur de l analyseur pour écarter tout risque d introduction dans l analyseur L admission d air de refroidissement pour le réacteur se situe au bas de l analyseur ne pas laisser de papier ou d aut...

Page 38: ...ici derivanti dal fluoruro cianuro o altri sali tossici Per evitare l inalazione di fumi pericolosi aggiungere idrossido di sodio o carbonato di sodio soda al contenitore dei rifiuti per neutralizzare gli acidi al suo interno Evitare la stratificazione dei rifiuti all interno del contenitore agitandolo di tanto in tanto Avvertenza Questo simbolo indica che per conformarsi alla Direttiva europea 20...

Page 39: ...attenzione quando si toccano componenti elettronici Avvertenza Qualora insieme all analizzatore venisse utilizzato un supporto per il montaggio è necessario che quest ultimo venga fissato al muro o sul pavimento prima di procedere all installazione del dispositivo Avvertenza La pressione del gas compresso nella bocchetta del gas dell analizzatore non deve superare 100 psig libbre per pollice quadr...

Page 40: ...o specificato dalla GE Analytical Instruments potrebbe essere compromessa la protezione prevista per l apparecchiatura Avvertenza Per individuare le tecniche appropriate di smaltimento fare riferimento alla scheda tecnica di sicurezza MSDS di accompagnamento a ciascun gruppo di standard e ai reagenti Avvertenza Per evitare pericoli tenere gli oggetti estranei lontani dalla ventola dell analizzator...

Page 41: ...6 41 of 270 DLM 68100 09 EN Rev A Avvertenza Quest attrezzatura deve essere collegata elettricamente a terra in conformità ai decreti e alle leggi locali o in assenza in conformità al Codice elettrico nazionale ANSI NFPA Numero 70 ...

Page 42: ... 警告有毒ガスから身を守るため必ず分析装置を換気の良い場所に設置してくださいサンプルの組成によっては塩素や臭素などのハロゲンまたはフッ化物シアン化合物その他の有毒な塩から出る有毒ガスが分析装置の廃液に放出される可能性があります有害ガスを吸入しないようにするため水酸化ナトリウム苛性アルカリ溶液または炭酸ナトリウムソーダ灰を廃液容器に加え廃液中の酸を中和します時々容器をかき混ぜて容器内で廃液が層を形成しないようにします警告この記号は EU の廃電気電子機器指令 WEEE に準拠しており分析機器を標準の廃棄物とは別に廃棄すべきであることを示します警告有害な試薬過硫酸ナトリウム塩化水素酸燐酸が分析機器で使用されます機器から出る排水は酸性であり正しい方法で廃棄する必要があります国州および地方自治体の政府規制に従ってください ...

Page 43: ...に接近する操作は人身傷害につながる可能性があります感電や火傷の危険性を回避するため分析機器を開く前に電源を切りコンセントから抜いてください電気部品に触れる場合は細心の注意を払ってください警告サンプル標準廃液または試薬が含まれる部品を取り扱う際は目の保護具と手袋を着用してください警告ディスプレイ画面には水銀が含まれお住まいの地域では有害物質に指定されている可能性がありますこの品目は国州および地方自治体の政府規制に従って廃棄してください警告分析は必ず分析機器の電源を切る前に停止してください警告これは等級 A 製品です屋内環境においてはこの製品は電磁干渉を発生することがありその場合はユーザーが適切な是正措置を取る必要があります警告この機器が GE Analytical Instruments によって指定された方法で使用さ...

Page 44: ... トで固定しておく必要があります警告分析器のガス注入口の圧縮ガスの圧力は 100psig 689kPa 以下でなければなりませんフィルターパネルアクセサリーのガスブローバック口の圧縮ガスの圧力は 40psig 276kPa 以下でなければなりません乾燥した油分を含まない空気または窒素のみご使用ください警告分析器に IP56 アクセサリーを使用する場合は必ずリアクターエア冷却口にフィルターを取り付けて分析器をご使用下さい警告新しいサンプルを分析する前に第三章障害をご参照下さい発生する可能性の高い障害とそれらが分析器に及ぼす影響について記載されています警告新しいサンプルを分析する前に第三章障害をご参照下さい発生する可能性の高い障害とそれらが分析器に及ぼす影響について記載されています警告こ...

Page 45: ...防止吸入有毒烟雾请确保将分析仪安装在通风良好的地方样品由多种成分组成氯或溴等卤素或氟化物氰化物或其它毒性盐发出的有毒烟雾可能会进入分析仪的废液之中为了防止吸入有害气体请向废液容器中加入氢氧化钠碱液或碳酸钠纯碱以中和废液中的酸应偶尔搅动容器中的废液以避免废液分层警告此符号表示符合有关废弃电气和电子设备 WEEE 的欧盟指令 2002 96 EC 分析仪应与标准废物隔离单独处置警告在分析仪中使用有害试剂过硫酸钠盐酸以及磷酸仪器中排出的废物流属酸性必须妥善处理请查询联邦州和当地政府的法规警告这是安全等级 I 级产品它必须连接到接地的电源上为避免对分析仪造成损坏并避免受伤要确保分析仪连接到电压正确的电源线上 ...

Page 46: ... 在打开分析仪之前请关闭电源并拔下电源线在接触任何电子器件时务必小心警告在搬运含有样本标准废物溶液或试剂的部件时请佩戴眼睛保护和手套警告显示屏幕可能含有汞而汞在您的所在地可能被认为是有害物质根据联邦州或当地政府法规处置此物品警告一定要在关闭分析仪之前先停止分析警告这是 A 级产品在室内环境中该产品可能会造成电磁干扰此时用户需要采取适当措施消除干扰警告如果该仪器以通用电气分析仪未规定的方式使用该仪器所提供的保护可能会受到损害警告查阅随每个标准组和试剂配备的物质安全数据表 MSDS 以确定正确的处置技术警告分析仪风扇附近避免置放异物以避免将有害物吹入分析仪用于反应器的冷却空气进口在分析仪的底部严禁纸张或其它物体堵塞或进入该入口 ...

Page 47: ...GE Analytical Instruments 2016 47 of 270 DLM 68100 09 EN Rev A 警告警告警告警告警告警告仪器上的此符号表示此产品不含有中国 RoHS II 列明的任何禁用物质 ...

Page 48: ...GE Analytical Instruments 2016 48 of 270 DLM 68100 09 EN Rev A 警告此设备必须按照地方法规和条例接地在没有地方法规的情况下必须按照美国电工法 ANSI NFPA 第 70 号的规定接地 ...

Page 49: ...xidizing agent The concentration of TOC in the sample can be calculated from the difference between the TC and IC concentrations i e TOC TC IC The sample also may be sparged with a gas to remove IC as CO2 when that is done the measurement is referred to as NPOC Non purgeable Organic Carbon measurements are appropriate when the sample is known to contain little Purgeable Organic Carbon POC The Anal...

Page 50: ...GE Analytical Instruments 2016 50 of 270 DLM 68100 09 EN Rev A Chapter 1 Introduction This page is intentionally left blank ...

Page 51: ... Analytical Instruments 2016 51 of 270 DLM 68100 09 EN Rev A Chapter 2 System Description System Specifications System Specifications for the InnovOx On Line TOC Analyzer follow starting on the next page ...

Page 52: ...e Pressure 125 psig maximum with provided control valve 0 5 psig minimum without optional sample pump Minimum Sample Flow Rate 50 mL min without optional sample pump Drain Gravity Drain Analyzer Specifications Outputs External USB Port 1 Internal USB Ports 2 Ethernet 1 Binary End of Analysis Output 1 Isolated 4 20 mA Analog Outputs 5 analytical 1 for stream ID Inputs Binary Input 1 for Remote Anal...

Page 53: ... for the analytical cycle is the same whether or not the Sample Backflush feature is utilized Sample Consumption Ox OL Sample 50 mL min and 125 psig See aliquot in respective range Filter Panel 1 0 L min w o exterior sample pump 400 mL min with exterior sample pump Temperature 60 C Fast Flush 10 mL Sample Flush Refer to aliquot volumes in respective range Monthly Carrier Gas Supply Pressure 30 to ...

Page 54: ...e measured 2 The sample pump accessory can be used to draw sample water to the multistream module from sources that are not pressurized 3 Sample handling module which draws sample into the Analyzer and mixes the sample with acid oxidizer and dilution water When NPOC is measured the sample is sparged in this module 4 Gas control module which controls the flow rates of carrier and sparge gas 5 The A...

Page 55: ...m controller board which contains Microprocessors and circuitry Ethernet and USB data outputs Color video graphics array VGA display with touchscreen Flash memory card 10 Input Output I O board which contains 4 20 mA analog outputs and digital inputs and outputs 11 Power Supply Power Entry universal ...

Page 56: ...8100 09 EN Rev A Chapter 2 System Description Figure 1 Analyzer Schematic NOTE This schematic is a flattened image of the Analyzer s components For a spatial representation of the fluidics layout inside the instrument refer to Figure 85 on page 211 ...

Page 57: ...ts to be used in the measurement 6 M phosphoric acid H3PO4 or 3M hydrochloric acid HCl referred to as Acid in the user interface is drawn into the sample coil first followed by the sodium persulfate Na2S2O8 reagent referred to as Oxid or Oxidizer in the user interface The purpose of the acid is to reduce the pH to 2 or less this converts any carbonate or bicarbonate salts to CO2 The volume of the ...

Page 58: ...ntrations of chloride Traditional TOC measurement techniques involving oxidation with persulfate are inefficient with those samples because much of the oxidizing power of the persulfate is consumed by the oxidation of the chloride However the InnovOx TOC Analyzer can oxidize chloride containing samples without excessive formation of chlorine because the salt is not soluble during the oxidation pro...

Page 59: ...tion of the IC and in the reactor by the oxidation of organics is separated from liquid in the gas liquid separator Then the CO2 is measured in the advanced NDIR detector This NDIR has been especially designed for use in the InnovOx TOC Analyzer It has no moving parts for long term reliability and it is constructed with durable materials that do not require the use of consumable absorbers to preve...

Page 60: ...oard for microprocessor controlled preparation of the sample reagents and dilution water Gas control module board for microprocessor controlled control of the carrier and sparge gases Reactor module board for microprocessor controlled oxidation of the samples NDIR module board for microprocessor controlled measurement of the CO2 produced in the Sample Handling and Reactor Modules Input Output boar...

Page 61: ...ation device most appropriate for the sample to be processed The following table lists available sampler configurations Clean Water Sample Options The Clean Water sample options include the 2 Stream Standard standard or high temperature option configuration and the 5 Stream standard configuration The standard configurations accommodate sample 3 Three 3 USB ports are provided for your convenience O...

Page 62: ...rds in 40 mL vials Samples also can be analyzed if they are in 40 mL vials using the vial port and Grab mode A port is provided for automated measurement of a check standard to ensure the Analyzer is operating properly and that it is in calibration Specifications 2 Stream or 5 Stream Clean Water Sampler The Clean Water Sampler is the default option and is intended for Cooling water Low suspended s...

Page 63: ...o sample flow The Wastewater Sampler therefore meets TSS requirements by creating clean water streams and samples free of particulates The Wastewater Sampler is substituted for the Clean Water Sampler and is available in a 2 stream or 5 stream configuration The Wastewater Sampler includes sample flow monitors with its own Fail Safe option For additional information see Installing the Wastewater Sa...

Page 64: ...gid piping suitable for the sample temperatures and any corrosive properties the sample might exhibit Mounting Stand A mounting stand is available which accommodates an Analyzer its reagents dilution water and check standard carboys and one sample filter panel The mounting stand allows the Analyzer to be mounted at various heights for convenience For safety the mounting stand must be bolted to the...

Page 65: ... and maintenance than the air purifier option but offers a lower initial purchase price The consumable scrubber cartridge must be replaced per the maintenance schedule presented in Table 15 2 Year Maintenance Worksheet Sievers InnovOx Online TOC Analyzer on page 196 Fail Safe Accessory If the Fail Safe accessory is selected sensors are installed in the Analyzer to detect when the flow rate of each...

Page 66: ... by back flushing with compressed air The sample filter panel is operated pneumatically so no electrical power is required The Analyzer controls the back flushing and the Filter Panel is adjustable for a wide range of particulate levels in the sample stream Sample Peristaltic Pump Some sample streams are not pressurized or are not sufficiently pressurized to provide the necessary flow to the Analy...

Page 67: ...zer in its waste stream The waste must either be kept basic or immediately discharged into an appropriate drain to avoid formation of toxic concentrations of those species in the air If the waste solution is collected excess sodium carbonate or sodium hydroxide should be added to its container before the analysis starts and the waste container should be actively mixed or periodically agitated to e...

Page 68: ...ively high levels of volatile organic compounds VOCs may require accelerated preventative maintenance of the sample tubing The Analyzer should be used in a well ventilated workspace Corrosive gases or vapors that are allowed to come in contact with the Analyzer will promote corrosion of certain components When the Analyzer runs highly acidic or caustic samples via the vial port or side sample port...

Page 69: ...ecific applications In North America contact GE Analytical Instruments Technical Support at 303 444 2009 or 888 245 2595 or techSupport GEAI ge com Technical support in Europe Middle East and Africa is available at 44 0 161 864 6800 or ServiceUK Instruments ge com Technical support in Asia Pacific is available at 65 62674659 or TechSupportSG GEAI ge com In other parts of the world contact your loc...

Page 70: ...GE Analytical Instruments 2016 70 of 270 DLM 68100 09 EN Rev A Chapter 3 Interferences This page is intentionally left blank ...

Page 71: ...e com Technical support in Asia Pacific is available at 65 62674659 or TechSupportSG GEAI ge com In other parts of the world contact your local GE Analytical instruments representative You can also visit the Support tab on our website at www geinstruments com Step 1 Unpack and Inspect the Analyzer Open the shipping box and remove the Analyzer from the packaging Verify that all items are present Si...

Page 72: ... gal carboy for check standard 5 gal carboy for dilution water Tubing for sample inlet 10 ft PVC sample control valves 2 or 5 depending on the Analyzer configuration USB flash memory drive Two 2 PVC conduit connectors strain relief hubs for conduit wiring Sealing washers for PVC conduit connectors Terminal ring for AC conduit ground wire 16 14 AWG Ferrites for I O cable Ethernet cables one cross o...

Page 73: ...t breaker or switch that disconnects both poles of the supply voltage rated appropriately Step 2 Complete the Identification Records Complete the Identification Records section on Identification Records on page 3 by recording the date of installation and the Analyzer serial number found on the side of the Analyzer Step 3 Select a Location for the Analyzer Select a location in a well ventilated are...

Page 74: ... adjusted so that the display of the Analyzer is approximately eye level but the spacing between the two horizontal braces must be 94 5 cm To mount a Filter Panel on the Mounting Stand attach the two Filter Panel brackets 30 5 cm apart as shown in Figure 2 Further instructions for installation of the Filter Panel are provided in the GE InnovOx Filter Panel Operation and Maintenance Manual 12 0 in ...

Page 75: ...lift the Analyzer onto the Mounting Stand Secure the Analyzer on the Mounting Stand refer to Figure 4 Lock the Analyzer onto the Mounting Stand using four 2 in 10 32 screws on both the top and bottom mounting brackets you attached to the Analyzer Tighten the screws down against the inside surface of the cross members of the Mounting Stand By friction these screws keep the instrument from moving ar...

Page 76: ...GE Analytical Instruments 2016 76 of 270 DLM 68100 09 EN Rev A Chapter 4 Installation Figure 4 Mounting the Analyzer to the Stand ...

Page 77: ...rument rack is not included in the accessories kit Hardware should be selected based on site specific circumstances Mounting hardware must be able to support four times the weight of the unit thus you should install mounting bolts capable of supporting 145 kg 320 lb Step 4 Connect the Waste Lines Connect the waste line as follows 1 Connect one end of the waste tube to the elbow barb labeled Waste ...

Page 78: ...of the Analyzer Do not place the waste container higher than that surface because the gas liquid separator will not drain properly Also try to minimize the length of tubing used and ensure a straight tubing path avoid bending the tubing Warning To protect against inhalation of toxic fumes make sure the Analyzer is installed in a well ventilated area Depending on the composition of the sample halog...

Page 79: ... barb until the center clear tube of the gas liquid separator is filled with water 5 Reconnect the tube to the barb Figure 6 The Gas Liquid Separator Step 6 Install Input Output Cables and Accessories The Analyzer s Input Output I O board is located in the top of the Analyzer under the access cover Remove the cover There are four terminal blocks on the I O board with TB1 located closest to the fro...

Page 80: ... the orientation of the terminal block before removing Completely loosen the screw for each pin you are connecting insert the wire tighten the screw and then gently pull on each connection to make sure the connection is secure Gently reinsert the terminal block into the board socket Starting from the front of the Analyzer the terminal blocks are as follows TB1 Analog Outputs The maximum 4 20 mA lo...

Page 81: ...ts are isolated from system ground 4 20 mA outputs are not individually isolated from each other and therefore are not intended to be connected to multiple systems with differences in ground potential 4 20 mA outputs may be configured by the user to output NPOC IC TC or TOC ppm levels Table 4 Stream ID Active Stream Stream ID Standby Output matches the standby level set for the first sequentially ...

Page 82: ...ary inputs are isolated from system ground and from each other The input should be supplied with a voltage from 11 volts to 24 volts and the input should be controlled by a relay or an open collector transistor Table 6 Alarm Outputs TB3 Pin Signal Function 1 BINOUT3_NO User Assigned Alarm 3 2 BINOUT3_COM 3 BINOUT3_NC 4 BINOUT4_NO User Assigned Alarm 4 5 BINOUT4_COM 6 BINOUT4_NC 7 BINOUT5_NO Analys...

Page 83: ...s relay to de energize until the error is cleared The Analysis Complete Output relay will energize momentarily pulse when the analysis is complete for every measurement Table 7 Alarm Outputs TB4 Pin Signal Function 1 24V 24 Volts 2 24V 3 24V 4 GND System Ground 5 GND 6 GND 7 BINOUT1_NO UserAssigned Alarm 1 8 BINOUT1_COM 9 BINOUT1_NC 10 BINOUT2_NO UserAssigned Alarm 2 11 BINOUT2_COM 12 BINOUT2_NC N...

Page 84: ...red in a variety of ways and is intended to execute a start stop command to the Analyzer from a remote location such as a Process Logic Control PLC System or Center Wiring examples are shown in Figure 8 and Figure 9 Figure 8 Wiring Option Binary Input using Analyzer s Internal Supply shows how the internal 24 VDC of the Analyzer on TB4 may be used to power the binary input No menu configuration is...

Page 85: ...l Supply Installing the Analysis Complete Output Connection The analysis complete binary output on TB3 may be used as a control signal to a sample sequencer device Once the binary output is wired properly the Analyzer will automatically provide a one second contact closure at the end of every sample analysis No menu configuration is necessary The binary output is active in the Online Check Standar...

Page 86: ...rms can be wired in both Normally Open NO and Normally Closed NC configurations Installing the Ethernet Connection The Ethernet connection provides an additional means of capturing data from the Analyzer Using Modbus commands may be issued to the Analyzer as well as collecting data Refer to Using the Ethernet Connection and Modbus on page 160 for details on the use of Modbus The Ethernet cable may...

Page 87: ...tem Controller Board Figure 12 Ethernet Cable Passing through Ferrite You also will need to set up the IP Address for the Analyzer For more information on network setup options see Connecting the Analyzer to a Network Via Ethernet on page 156 or Configuring a Personal Computer on page 157 Installing the USB Connection The USB port is intended to provide data transfer to a USB flash memory drive or...

Page 88: ...near the Analyzer and be clearly marked as the disconnecting device for the Analyzer Remove the pass through cap from the port labeled AC INLET on the right side of Analyzer Secure the PVC conduit connector strain relief hub and washer to the conduit and the Analyzer panel in the normal manner Route the AC power conduit through the pass through port AC connections inside the Analyzer are made to t...

Page 89: ...flexible 1 4 in 6 mm ID tubing provided with the Analyzer to the sample source Connect the other end to the barbed fitting nearest the Analyzer on the Sample Cup inlet fitting The one quarter turn PVC ball valves provided in the accessories kit may be used to control sample flow if the sample pressure is high If the sample stream does not have sufficient pressure to flow through the Sample Cup the...

Page 90: ...to attach the bracket to the side of the Analyzer and install the sampler pipe assembly using one of two configurations velocity method or the overflow method as described in the following procedures NOTE In 5 stream Analyzers Pump 1 may be used to pump Stream 1 and 2 Pump 2 may be used to pump Stream 3 and 4 Do not mix the Streams and Pumps 2 Stream Option 5 Stream Option Original Clear New Opaqu...

Page 91: ... allowing solids to flow by the sample tube and preventing them from being drawn into the instrument See Figure 15 Velocity Method Flexible 1 tubing is included with the Kit for the supply and drain side of the Wastewater Sampler pipe assembly When configuring for velocity mode operation use the 3 4 NPT to 1 barb fittings for the outlet pipe of the sampler 1 Attach and secure the Wastewater sample...

Page 92: ...treams you are installing Figure 18 Velocity Method Barb Fittings Identification 3 For this Velocity method install a large size barb into the open end of the sample inlet pipe the pipe with the internal sipper tube needle 4 Insert a Wastewater Sampler pipe assembly into the two bracket clamps located on the outside of the Analyzer For velocity method ensure that the pipe with internal sipper tube...

Page 93: ...he bulkhead to the fitting on the top of the sipper tube 8 Test the proper adjustment of the sipper tube by performing a sample flush and verifying that no bubbles are pulled through the clear inlet tubing 9 Repeat steps 3 through 8 for each stream 10 If you are also installing the fail safe option cut and remove the tie wrap used to secure the sensor to the Analyzer during shipping 11 Remove the ...

Page 94: ...ay break the sensor 13 If you have the fail safe option repeat steps 10 through 12 for each stream 14 Connect the pipe farthest from the instrument the pipe without the internal sipper tube to the sample source See Figure 19 Velocity Method Installation on page 93 15 Connect the pipe nearest the instrument the tube with the internal sipper tube to the waste outlet See Figure 19 Velocity Method Ins...

Page 95: ...ows The screws are taped to the side of each bracket Top bracket Slide the following bracket over the plate adapter and secure it by tightening a screw on each end of the plate adapter Figure 23 Top Wastewater Sampler Bracket w Plate Adapter Lower bracket Hold the following bracket so that the screw holes are aligned with the available screw openings on the Analyzer and secure with the provided sc...

Page 96: ...sembly and a small size barbed fitting for each of the streams you are installing Figure 26 Overflow Method Barb Fittings Identification 5 For Overflow method install a small size barb into the open end of the sample inlet pipe This is the pipe with the internal sipper tube needle 6 Locate the filter vents located in the Wastewater Sampler Kit NOTE Leave the pre installed barb inside the other pip...

Page 97: ...clamp located on the outside of the Analyzer For this overflow method ensure that the waste drain pipe without internal needle is installed farthest from the instrument Also ensure that the sample inlet pipe is installed nearest to the instrument Figure 27 Overflow Method Installation 9 Close the two clamps over the pipe and use pliers or channel locks to secure 10 Adjust the height of the sipper ...

Page 98: ... use an additional tool to tighten as this may break the sensor 16 If you have the fail safe option repeat the steps 13 through 15 for each stream 17 Connect the pipe nearest the instrument the pipe without the internal sipper tube to the sample source See Figure 27 Overflow Method Installation on page 97 18 Connect the pipe farthest from the instrument the pipe without the internal sipper tube to...

Page 99: ... Connect the dilution water Connect the persulfate oxidizing solution 30 w v sodium persulfate Na2S2O8 Connect the acid 6M H3PO4 or 3M HCl To connect the dilution water 1 Attach one end of the tubing to the top port and tighten the PEEK nut finger tight 2 Insert the other end of the tube assembly into the opening of the carboy 3 Fill the Dilution Water carboy with deionized water or the best quali...

Page 100: ...s and as sparge gas This requirement can be satisfied using compressed air if the optional Regenerative Air Purifier is installed The Air Purifier removes CO2 and moisture from compressed air that is pressurized from 50 to 100 psig 138 to 689 kPa The minimum air demand flow capacity is determined by the pressure applied Determine the required purge purifier air inlet and flow based on the supply o...

Page 101: ...accumulation on sensitive components The tube from the gas source used for the carrier and sparge gas may be teed to also provide gas to the IP56 accessory After installing the tee in the gas tubing press a 1 4 in OD flexible tube such as polyethylene tubing into the inlet of the Gas Filter mounted on the right side of the Analyzer Tubing from the outlet of the filter is connected to the OPTIONAL ...

Page 102: ... If the waste lines were not attached already do that now see Installation Step 4 When ready press the Main button on the display Setting the Clock Set the Analyzer clock to ensure that all TOC measurements reflect the correct date and time as follows 1 Press the Menu button 2 Select the Maintenance tab 3 Press the Advanced button 4 Press the Clock button 5 Specify the correct date and time via ea...

Page 103: ...5 Dependant upon COD of the sample5 Rej 0 Flush Off 8 Ensure that the other settings in the Protocol Setup Advanced Setup screen are Sparge 0 8 min Blank Correction Off If any of the settings need to be changed press the button that is to be changed and the choices will show up on the right side of the screen as described above 9 Press Back then select the Maintenance tab 10 Press the Flush Reagen...

Page 104: ...Main screen A graph of the CO2 peaks will be displayed Each peak appears after its peak height is measured and the measured NPOC concentration appears at the top of the screen 14 When the analysis is complete the CO2 peaks will be displayed on the screen If there are no peaks and the Mass Response axis is only 1 0 µg full scale then refer to the Troubleshooting section of this manual Otherwise pro...

Page 105: ... best results make sure to rinse with one Reagent Water vial in between the IC and TOC vials These points can be individual calibration standards of different concentrations or the Auto Dilution feature can be used When Auto Dilution is selected the Analyzer automatically dilutes a standard solution to a lower concentration selected by the operator When an application involves measurement of sampl...

Page 106: ...ttle containing reference materials prior to pouring into vials Remove vial caps only when prepared to pour standards and replace caps immediately after pouring Avoid handling of vial septa Also avoid touching the top of the vial to protect against introducing foreign particles TOC and IC Wear gloves when preparing standards Pour standards in a clean area to avoid introducing contaminants Prepare ...

Page 107: ...ne Analyzer using either the Single Point Calibration or Two Point Calibration the algorithm used to calculate the slope of the calibration curve uses the following variables The mass response The ratio of sample volume to total volume where total volume includes sample dilution water reagents and so on The concentration of the standard e g 1000 ppm Slope7 standard concentration Vs Vt mass respons...

Page 108: ...int If the highest accuracy is sought calibrate using at least two points The concentration of the calibration point in a single point calibration should be greater than the expected concentration of the samples but not exceed them by too much Because Auto Dilution contributes some uncertainty to the calibration single point calibrations using Auto Dilution normally are not recommended If you plan...

Page 109: ... have to be reagent water TOC 0 1 ppm in order to bracket the concentrations of the samples When you plan on measuring TOC TC IC in your samples it is recommended that the first calibration point for the TC and IC portions be reagent water This will ensure that the best linear response will be achieved for both TC and IC regardless of the variability of the individual concentrations Figure 32 depi...

Page 110: ...low this measurement approximates the TOC concentration in the reagents and dilution water for the particular volumes of reagents and dilution water used in the calibration The Analyzer corrects the calibration for the TOC in the reagents and dilution water by setting the measurement measured response i e Mass Response to equal 0 ppm The operator enters the concentration of point 2 into the calibr...

Page 111: ...ge be calibrated using a six point point to point calibration see page 112 The recommended points are Reagent Water 100 ppm 1 000 ppm 5 000 ppm 20 000 ppm and 50 000 ppm Calibration with More than Two Points When the calibration is performed with three to six points multi point calibration the user has the choice of having the Analyzer calculate the calibration constants from a linear fit of the p...

Page 112: ...picts a point to point calibration with 6 points Like the linear fit the point having the lowest concentration is measured first and the points must increase in concentration at each step Point 1 can either be reagent water or a higher known concentration The Analyzer calculates an intercept and slope for the line connecting each pair of points as shown in Figure 35 When this calibration is later ...

Page 113: ...iate analysis range is performed in this range For best performance of the Auto Range feature it is recommended that the 50 000 ppm range be calibrated using a six point point to point calibration The recommended points are Reagent Water 100 ppm 1 000 ppm 5 000 ppm 20 000 ppm and 50 000 ppm Auto Dilution If you are calibrating with multiple points within a range you can use one standard and the An...

Page 114: ...ommended to use the blank correction feature In order to perform a calibration with blank correction on first calibrate the Analyzer in TOC mode in the Up to 1 000 ppm range with blank correction off Then perform the blank measurement using that calibration See Measuring the Blank on page 151 for the procedure Calibration Groups If you are using the Analyzer s Auto Range function you will need to ...

Page 115: ...button 3 Press the System Properties button 4 Make sure that the USB flash memory drive is attached to the USB port8 5 Press the USB Backup button NOTE The factory default values may be used however these values are not as accurate as the actual calibrations If you want to use a factory default calibration for one of the ranges do NOT press the default button and then select the calibration for th...

Page 116: ...section To perform a calibration that is not blank corrected 1 Consider installing fresh dilution water if it is more than a few days old 2 Perform a flush of the reagents and dilution water Maintenance Flush Reagents Flush All Rinse down the Analyzer if it has been analyzing samples more concentrated than the first lowest concentration calibration point Rinse down can be expedited when necessary ...

Page 117: ...C TOC or IC standard concentration for the calibration point Enter a value with up to two decimal places such as 1 25 The type of standard is shown in gray at the bottom of the screen e g NPOC Standard IC Standard Rinse or TOC Standard Press the Reps button to change the number of measurements repetitions the Analyzer will make for this calibration point see Table 9 Press the Rejects button to cha...

Page 118: ...mpleted measurements on all standards vials the Calibration Summary screen displays the following values Refer to Figure 36 on page 120 Expected Indicates the expected concentration of the calibration point When Auto Dilution is Off the expected concentration is the Certified Concentration of the standard For reagent water there is no expected concentration so the entry is N A When Auto Dilution i...

Page 119: ...he calibration See Section Editing a Calibration on page 120 Export PDF Permits user to export calibration results in PDF form to a USB flash memory drive Apply Saves the new calibration constants 6 To export a PDF when the calibration is completed containing the results of the calibration insert a USB flash memory drive into the external USB port9 and then press the Export PDF button It is strong...

Page 120: ...tion is complete see Figure 37 The column on the left of the new display shows the concentration of the standard at each calibration point The next column displays the repetition number The measured value for each repetition appears in the third column and the fourth column displays the Difference between the measured value and the concentration of the standard The fifth column identifies whether ...

Page 121: ...ation protocols in total For more detailed information regarding options available under verification menus consult the relevant sections describing calibration keeping in mind that you must press the Verification button rather than the Calibrate button in the Cal Ver tab and for each verification protocol you must specify a calibration protocol for the measurements Table 10 lists the approximate ...

Page 122: ... To export all of the calibrations or verifications on the list press the Export All button Then press the button that corresponds to the desired data format CSV or PDF To export calibration or verification summary data to a USB flash memory drive make sure a USB flash memory drive is connected to the Analyzer s USB port Only one USB flash memory drive should be inserted at a time in one of the th...

Page 123: ... contact information and the firmware version number The Analyzer then begins initialization to check the status of consumables and prepare for making measurements When the Analyzer is done with initialization press the Main button to display the Main screen The Main Screen The Main screen provides important status information for the Analyzer As shown in Figure 38 the Main screen identifies the t...

Page 124: ... the screen that identify the sample streams that are enabled and whether or not the Check Standard is enabled For example when Stream 1 is enabled the S1 tab appears and so on When the Check Standard is enabled the CS tab appears Figure 39 Figure 39 The Main Screen Online Mode The Main screen provides the following options Menu button Press this button to display the Menu screen and change the An...

Page 125: ... or data from each enabled stream CS tab When making Online measurements select this tab to display peaks or data from the Check Standard if it is enabled Current tab Select this tab to see the CO2 peaks from whichever stream or Check Standard the Analyzer is currently measuring The Menu Screen The Menu screen Figure 40 provides you with access to all Analyzer settings and configuration options Th...

Page 126: ...en to initiate measurements This button is also visible from any other tab Setting Up Measurements The Setup Tab Use the Setup tab to define the measurement settings for the Analyzer The Setup tab includes the following options Online Set up a selected number of online measurements on each one or more enabled sample streams and the check standard if it is enabled Check Standard Set the Analyzer to...

Page 127: ...nts of Stream 1 are made without a pause with two exceptions Figure 41 Continuous Operation The first exception is the Check Standard since it is enabled Measurements of the Check Standard are made according to the schedule established by the operator In the example shown in Figure 42 the check standard is measured every three hours the Check Standard Frequency Since two Repetitions have been sele...

Page 128: ...on is employed streams are also skipped whenever a stream stops flowing When flow resumes in that stream the Analyzer will measure it again in its original sequence Cycle Frequency Many users prefer to obtain a TOC measurement of each stream every hour every two hours and so on The Cycle Frequency setting makes it easy to make these periodic measurements To set the Cycle Frequency the Continuous s...

Page 129: ...f measurement selected NPOC TOC and so on Whether or not AutoRange is selected In the example shown in Figure 43 the Run Time is 1 5 hours As the graph indicates the Run Time must be less than the Cycle Frequency If you select an incorrect Cycle Frequency that is less than the Run Time the Analyzer will automatically display a notification message and will not start analysis To aid in the setup pr...

Page 130: ...le Frequency press No Figure 44 Calculating the Run Time Adjust the Run Time by reducing the number of repetitions on one or more Streams or the check standard Also consider making the measurements in ways that take less time Auto Range measurements require more time than when a particular Range is selected Possibly one or more measurements can be made with fewer or no Sample Flushes ...

Page 131: ...ly Flush Daily Flush Start You can also calculate Run Time and view a Summary of online configuration on this screen Operation with Multiple Streams The InnovOx On Line TOC Analyzer may be used to monitor multiple streams The base configuration can monitor two streams and five streams can be monitored with the optional 5 Stream configuration With the exception of the number of streams both Analyze...

Page 132: ...reen 4 Press the Range button to display the range buttons Press a button for the specified range such as Up To 1 000 or press Auto to have the Analyzer use the Auto Range function For more information on the Auto Range function see Auto Range on page 144 5 Press the Measure button to specify which value to measure IC NPOC TOC or TC 6 Press the Advanced Setup button to display the following option...

Page 133: ...orm a Test Analysis on page 102 and Oxidizer on page 145 9 Press the Reps button to change the default setting for the number of measurements repetitions the Analyzer will make for this stream 10 Press the Flush Blowback Setup button to configure flushes and or the blowback operation of the optional Filter Panel See Chapter 7 Operation with the Filter Panel for information on the blowback operatio...

Page 134: ...nd then configure any other streams you want to monitor 16 Continue to the next section to define the setup for the check standard Check Standards Check standard measurements provide a way of checking that the Analyzer is operating properly and that its calibration has not changed The Analyzer can make measurements of this check standard a solution of known concentration as part of a scheduled Onl...

Page 135: ...he check standard 3 Press the Start Time button to set the start time using a 24 hr clock format e g use 13 00 for 1 p m 4 Press the Concentration button to set the ppm concentration of the check standard 5 Press the Tolerance button to set the acceptable range of concentrations for the measurement of the standard For example if the Tolerance is set at 20 then the acceptable concentration is 20 be...

Page 136: ...16 Press the Flush button to configure flushes Press the Dilution Water Flush button to rinse out salts or particulates from the reactor and its seals Press the Sample Flushes button to flush the Analyzer with the new check standard Up to five Sample Flushes may be selected Use Sample Flushes to quickly reach steady state response when the Analyzer will be switching from one stream to another and ...

Page 137: ... Range on page 144 8 Press the Acid button to specify the percent of this reagent to use in the protocol 9 Press the Oxidizer button to specify the percent of this reagent to use in the protocol 10 Press the Reps button to change the default setting for the number of measurements repetitions the Analyzer will make for this stream 11 Press the Rejects button to change the number of check standard m...

Page 138: ...d the Analyzer will back flush the enabled sample stream inlet s with acid reagent during the Daily Flush The Clean Inlet function aids in controlling biological growth in the sample cup and inlet tubing Auto Restart When the Auto Restart function is On the Analyzer will resume analysis when power is restored after a power outage When Auto Restart is Off the Analyzer will remain in Standby when po...

Page 139: ...p tab Online button Configure Online to display the current configuration for all streams and the check standard press the Summary button The summary is a convenient way to verify the configuration before starting the analysis Grab Measurements Use the Grab option to specify settings for Grab analysis when performing analysis on samples contained in 40 mL vials placed in the Vial Sampler To specif...

Page 140: ...tions the Analyzer will make for this sample If Repeat Criteria is ON then this field will be grayed out and uneditable Press the Rejects button to change the default setting for the number of measurements the Analyzer should exclude from its calculations If Repeat Criteria is ON then this field will be grayed out and uneditable Press Repeat Criteria to allow the Analyzer to follow configurable lo...

Page 141: ...libration to use in this protocol Press the Save button to overwrite the modified protocol or press the Save As button to save as a unique name Enter a name for the new protocol and then press the Save button If the Save As button is selected you will be prompted to enter a new name The new protocol now appears on the Protocol screen 6 Press the Start Analysis button The Sample Name screen with a ...

Page 142: ...er Auto Range NPOC 7 6 5 3 7 TOC 3 2 1 0 3 IC 7 6 3 1 7 TC 3 2 1 0 3 100 ppm Range NPOC 6 5 4 2 6 TOC 3 2 1 0 3 IC 6 5 3 1 6 TC 3 2 1 0 3 1 000 ppm Range NPOC 7 6 5 3 7 TOC 3 2 1 0 3 IC 7 6 4 2 7 TC 3 2 1 0 3 5 000 ppm Range NPOC 14 13 12 10 14 TOC 12 11 10 5 12 IC 14 13 11 9 14 TC 12 11 10 9 12 20 000 ppm Range NPOC 20 20 20 20 20 TOC 20 20 20 20 20 IC 20 20 20 20 20 TC 20 20 20 20 20 50 000 ppm ...

Page 143: ...eck Standard carboy Measurement Settings Measure The Analyzer allows you to make NPOC TOC TC and IC measurements NPOC is measured by adding sample acid oxidizer and dilution water to the Sparger The solution is mixed and any IC in the solution is converted to CO2 by the acid Then CO2 free gas is bubbled through it to remove that CO2 A portion of the sparged solution is then introduced into the Rea...

Page 144: ...Analyzer will require a significant time to rinse that material out of the reactor and high pressure valves At worst the reactor may require disassembly and cleaning If you do not know the approximate TOC level in your sample then you can use the Auto Range function as described in the following table Auto Range Use the Auto Range setting to let the Analyzer determine the best range for the curren...

Page 145: ...loride brines have been found to require oxidizer percentages as high as 30 or more For best shelf life the oxidizer should be kept out of sunlight and maintained at 15 25 oC See also step 7 in Step 12 Perform a Test Analysis on page 102 Repetitions Set the number of repetitions to the number of measurements to make on a Grab sample Online or Check Standard measurement The maximum number of repeti...

Page 146: ...his flush removes any salt or particulates from previous measurements The second type of flush is the Sample flush Select one to five Sample flushes if the sample to be measured is thought to be a much different concentration than the previous sample During a Sample flush the Analyzer prepares the sample acid oxidizer and dilution water if required in the same proportions that will be used in the ...

Page 147: ...Conversion Factor button Figure 52 to access the five available conversion factors Factor 1 Factor 2 Factor 3 Factor 4 and Factor 5 3 Press the Factor 1 button or other Factor button to configure that factor The Factor screen appears with configurable Factor Equation Factor Units and Factor Name buttons Figure 53 Figure 53 Configuring a Conversion Factor 4 To set up a Conversion Factor equation pr...

Page 148: ...or is used Figure 54 Configuring the Factor Equation 5 Press the Save button to save the equation and return to the Factor screen 6 Press the Factor Units button and use the alpha numeric keypad to type the units identifier up to 10 alpha numeric characters such as MG PER L Figure 55 Figure 55 Configuring the Factor Units 7 Press the Save button to save the units and return to the Factor screen ...

Page 149: ...utton to save the conversion factor name and return to the Factor screen 10 Press the Back button to access the other available conversion factors 11 Repeat steps 3 through 10 for each conversion factor to configure Each configured conversion factor now appears when setting up Stream measurements or Grab measurements Figure 57 as described earlier in this chapter To apply a conversation factor pre...

Page 150: ... less than about 10 ppm of TOC or NPOC For the greatest accuracy the TOC or NPOC measurements should be corrected for those contaminants the blank There are two ways of making this correction If all of the sample streams are to be measured using the same Acid and Oxidizer settings used in the calibration then the simplest way is to calibrate the Analyzer using Reagent Water as the first calibratio...

Page 151: ...sure the Blank 1 Ensure that the Analyzer is rinsed down 2 Select the Cal Ver tab 3 Press the Blank button 4 Press the Calibration button to select the TOC mode calibration to use when measuring the blank If you do not specify a calibration the Analyzer will use the default TOC calibration for the 1000 ppm range Highlight a calibration and then press the Select button 5 Press the Start Blank butto...

Page 152: ...isplays the data collected for the corresponding stream Vial Port Displays data obtained from measurements made at the Vial Port Check Standard Displays the check standard measurements 3 Touch the screen or use the Page Up Page Down buttons to move through the list of sampling data that appears To view data starting at a specific date press the Go To button and use the date buttons to specify the ...

Page 153: ... on page 159 Figure 59 Export Data Screen To export data history To export data using the Ethernet port you must first configure the Analyzer s IP address see Connecting the Analyzer to a Network Via Ethernet on page 156 1 Select the Data tab and then press the Export button The Export screen appears 2 Press the Range button to select the time frame for the data to export The following buttons app...

Page 154: ...rt Data Screen 4 Press one of the following buttons to select and execute a format for the data export CSV to USB Exports a comma separated text file to a USB flash memory drive CSV to Ethernet Exports a comma separated text file via the Ethernet port Export PDF to USB Exports a PDF file to a USB flash memory drive 5 Press the Back button to return to the Data tab ...

Page 155: ...ppm 7 IC ppm 8 TC ppm 9 Converted Result 10 Unit 11 Reject Y or N 12 Acid 13 Oxid 14 Range Mode Manual or Auto 15 Range Up to 100 Up to 1 000 Up to 5 000 Up to 20 000 Up to 50 000 16 Sparge min 17 Flush OFF DI 1S 2S 3S 4S or 5S 18 Blank Correction ON or OFF 19 Resuspend OFF 20 Pressure psi Ambient pressure psia 21 Man Dilution Manual Dilution Numeric Value 22 Calibration Name Alphanumeric characte...

Page 156: ...If you connect the Analyzer directly to a personal computer use an Ethernet crossover cable Configuring the Analyzer s IP Address You must configure the Analyzer s Internet Protocol IP settings for use in connecting the Analyzer to a computer network or directly to a computer To configure the Analyzer s IP Address 1 Select the I O tab and then press the IP Configuration button The Configuration sc...

Page 157: ...of the IP address MUST be the same as those used on the personal computer GEAI recommends leaving the IP address set to the default value of 192 168 1 10 4 If you selected Manual in Step 2 you must enter a Subnet Mask as follows If you are connecting to the network via a standard Ethernet cable enter the subnet mask address provided by your Information Technology Group If you are connecting the An...

Page 158: ... mask address This should be the same numbers as those used on the Analyzer 9 Click the OK button 10 Click the OK button 11 Click the Close button 12 Shut down power off and restart the computer To manually set the IP address for Windows XP 1 On the computer click the Windows icon located on the lower left of the screen and then select Control Panel Network and Sharing Center 2 Double click the Lo...

Page 159: ...ter a subnet mask address This should be the same numbers as those used on the Analyzer 10 Click the OK button 11 Click the OK button 12 Click the Close button 13 Shut down power off and restart the computer Collecting Historical and Real Time Data Collect historical or real time measurement data from the Analyzer using Ethernet and a data acquisition program For additional information see Install...

Page 160: ...ddress on page 156 The InnovOx TOC Analyzer uses the standard Modbus port 502 for Ethernet communication The Modbus map for InnovOx is provided in Appendix D Modbus Map Configuring Alarm Outputs The Analyzer has four binary alarm outputs which can provide an alarm on any stream when the concentration in that alarm exceeds a threshold value To set the alarms 1 Select the I O tab 2 Press one of the ...

Page 161: ... numeric keypad that appears to the right to set the threshold concentration in ppm units10 Any measurement below this threshold will trigger the alarm 7 To activate the alarms press the Alarm On Off button and then press the On button that appears 10 The unit of measure appears in the default ppm unit or another unit measure if the stream s Setup screen has been configured with a conversion facto...

Page 162: ...n appears 3 Press the Reset button The Analyzer resets the alarm The alarm is still active and will be output the next time the concentration exceeds the selected threshold value Printer Setup You can print data from the Analyzer directly to a USB connected printer The InnovOx is capable of communicating to the following list of printers DeskJet 3050 DeskJet D1341 LaserJet Professional P1102w Offi...

Page 163: ...sensor When a liquid leak is detected the Analyzer reports this error displays a pop up message and stops analysis The I O tab contains a Liquid Sensor Setup button for GEAI factory technician use to enable the liquid sensor before a new Analyzer and any optional Hazardous Location enclosure ATEX or C1 D2 is shipped To enable a liquid sensor 1 Verify that the Analyzer has a liquid sensor installed...

Page 164: ... installed on the lower left inside wall of the enclosure If you are unsure of the presence of a liquid sensor do NOT enable this feature 7 Select the I O tab 8 Press the Liquid Sensor Setup button The Main Enclosure Liquid Sensor and Auxiliary Enclosure Liquid Sensor buttons appear 9 Press the Auxiliary Enclosure Liquid Sensor button and press the Enabled button 10 Verify that the Auxiliary Enclo...

Page 165: ...nsistent periods of time To access the Advanced screen select the Maintenance tab and then press the Advanced button Figure 66 The Advanced Screen Setting Analyzer Name and Location Specify the name and location for the Analyzer so that data history and printed output reflect the source of your measurements To set a name for the Analyzer 1 Select the Maintenance tab 2 Press the Advanced button The...

Page 166: ...ry However you may need to refer to the original factory settings Before you begin customizing the parameters and running analysis data export and save these system properties To save and export the system properties 1 Select the Maintenance tab 2 Press the Advanced button The Advanced screen appears 3 Press the System Properties button The System Properties screen appears Figure 67 System Propert...

Page 167: ...n select the Upgrade button This process may take several minutes Gas Valve PID Parameters The InnovOx Analyzer contains Gas Valve parameters that have been previously set at the factory using the default setting of PID Set 2 In the case where an instrument is upgraded in the field from firmware versions 3 06 to versions 3 07 the Gas Valve PID parameter may need to be changed The determining facto...

Page 168: ... Screen button NOTE The Run PID Test button also appears and is typically used by the Factory or On Site Service The test activates an automatic diagnosis and setting by the Analyzer for the type of gas manifold currently installed The Run PID Test can take several minutes after which the Analyzer displays one of the following test results and automatic settings PID Test Passed Using Set 1 PID Pas...

Page 169: ...f to disable the Fail Safe option which is helpful when performing maintenance procedures To set the Fail Safe option 1 Select the Maintenance tab 2 Press the Advanced button 3 Press the Fail Safe button and then press either the On or Off button Setting the Keyboard Options Specify the manner in which the Keyboard will be displayed standard QWERTY mode or Alphabetical mode 1 Select the Maintenanc...

Page 170: ...ncel Shutting Down the Analyzer To ensure that you do not lose any data always shut down the Analyzer using the on screen menu before using the power switch To shut down the Analyzer 1 Make sure analysis is stopped 2 Select the Maintenance tab 3 Press the Shutdown button The Confirm Shutdown dialog box appears 4 Press Yes and allow approximately 30 seconds for the firmware to close The screen will...

Page 171: ...ition 2 Press the touchscreen to start the Analyzer Checking the Software Version You can view the software version of the Analyzer for your reference or to aid in troubleshooting activities To check to the software version 1 Select the Maintenance tab 2 Press the Software Version button The main software version appears on top This is the same version number that displays when the Analyzer starts...

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Page 173: ...some cases the water pressure in the feed line is not sufficient to flow through the Filter Panel through the filter screen and to the Analyzer In those cases it is necessary to pump the filtered water from the Filter Panel to the Analyzer The InnovOx On Line TOC Analyzer can accommodate an optional external peristaltic sample pump to overcome inadequate line pressure The pump is controlled by the...

Page 174: ...y the Analyzer This delay is evident before the Sample Flush and before sampling begins for the first repetition It also exists before sampling begins for the subsequent repetitions but it is less evident because the Analyzer is completing repetition 1 while it is preparing the sample to be used in repetition 2 To set up operation of the Filter Panel 1 Stop any analysis 2 Confirm that sample water...

Page 175: ... signal air tube should be inserted in Air to Filter Panel port 1 5 Confirm that compressed air is connected to the Blowback Air port on the Filter Panel 6 Go to the Stream setup screen Setup tab Online Configure Online for the stream where the Filter Panel is installed Figure 70 Figure 70 Stream Setup Screen 7 Press the Flush Blowback Setup button The Flush Blowback Setup screen appears Figure 71...

Page 176: ...g the keypad that appears to the right and then press Enter Sample Flushes Number of flushes to include Pulses Number of pulses to include Sample Flow Time Delay time in seconds 10 Press the Sample Back Flush button and then press either the Enabled or Disabled button that appears When enabled this flush will occur at the end of every measurement 11 Repeat this procedure for each stream installed ...

Page 177: ...rtSG GEAI ge com In other parts of the world contact your local GE Analytical instruments representative You can also visit the Support tab on our website at www geinstruments com This chapter covers replacement instructions for all routine maintenance items that are replaced on a regular schedule instructions for non routine maintenance items are provided in those items packaging A one year maint...

Page 178: ...lso be provided Periodic Maintenance Tasks Periodic Inspections To ensure optimum performance of the Analyzer inspect the following items periodically 1 Reagent levels Inspect the reagent and dilution water containers to ensure that there is adequate acid oxidizer and dilution water to perform the analyses11 Prepare the reagents if necessary according to the directions in the following section 2 C...

Page 179: ...perly and that its calibration is accurate12 Preparing the Oxidizer Solution The following figure shows how the strength of 30 W V sodium persulfate solution decreases with time at 5 C 25 C and 40 C These data were obtained with reagent grade sodium persulfate in low TOC reagent water while the solution was stored in high density polyethylene HDPE bottles of the type used with the InnovOx Laborato...

Page 180: ...omparable water until it reaches the appropriate 1 2 3 or 4 bottle fill mark identified on the carboy 3 Shake the carboy for approximately one minute to mix the oxidizer powder with the water Preparing the Acid The InnovOx On Line TOC Analyzer is designed to operate with either of two different acids 6 M phosphoric acid H3PO4 and 3M hydrochloric acid HCl Phosphoric acid is preferred where salts in...

Page 181: ...pad lightly applied with a spray cleaner Isopropyl Alcohol may be used but ensure that all solvent residue is removed Water may cause damage or discoloration of the polarizer Clean any condensation or moisture from any source immediately Before cleaning the screen you can temporarily deactivate touchscreen sensitivity for 30 seconds To deactivate the screen 1 Press the Menu button and select the M...

Page 182: ...separator apart over an appropriate waste receptacle and dispose of the water 7 Rinse the gas liquid separator with water to remove any residue inside it 8 Reassemble the gas liquid separator 9 Fill the gas liquid separator with DI water from the center port on top until the clear tube on the gas liquid separator is completely full 10 Secure the gas liquid separator to the bracket by tightening th...

Page 183: ...at connect the sparger to the bracket 6 Remove the sparger from the Analyzer 7 Disconnect the electrical connector attached to the mixer on the sparger M2 SH 8 Gently pull the sparger apart Be sure to open the sparger over an appropriate waste receptacle Remove the mixing bar 9 Rinse the thru ports of the sparger and the mixing bar with water 10 Reassemble the sparger with the mixing bar 11 Reconn...

Page 184: ...cate the syringe Before you begin locate the Syringe Lubrication Kit that came with the Analyzer s Accessory Kit You will also need to provide a 3 32 in Allen hex key wrench 1 Turn off the water supply to the Analyzer If the Analyzer is taking measurements press the Stop Analysis button 2 Using the Maintenance screen shut down the Analyzer 3 Turn off the power to the Analyzer and unplug the power ...

Page 185: ...e the screw that secures the syringe Remove any washers under the block and retain them for re installation Figure 75 Locating the Syringe Screw and Washers 6 Unscrew the syringe base by turning the base to the left Figure 76 Unscrewing the Syringe Base Washers If these washers are NOT installed with your Analyzer ignore this step ...

Page 186: ...om the valve The washer should remain in the valve If the washer comes free of the valve when you remove the syringe be sure to capture the washer for re installation You must place the washer back on the plunger tip when reinstalling Figure 77 Removing the Syringe 8 Pull the plunger all the way out of the syringe barrel Figure 78 Pulling Out the Plunger ...

Page 187: ...1 Swirl the syringe tip once in the slightly moistened wipe and reinstall it into the syringe barrel Cycle two or three strokes to ensure adequate distribution of the lubricant Figure 80 Distributing the Lubricant 12 Position the lubricated syringe under the valve 13 Screw the syringe base into the threading in the valve by turning the base to the right 14 Using a 3 32 Allen wrench tighten the scr...

Page 188: ...55 2595 for a replacement kit Technical Support in North America is available at 303 444 2009 or 888 245 2595 or techSupport GEAI ge com Technical support in Europe Middle East and Africa is available at 44 0 161 864 6800 or ServiceUK Instruments ge com Technical support in Asia Pacific is available at 65 62674659 or TechSupportSG GEAI ge com In other parts of the world contact your local GE Analy...

Page 189: ...ses the valve V7 R is normally open so the first press will close the valve 6 Pull the sample tubing out of the valve and then disconnect the tubing from the barb at both ends 7 Connect each new piece of tubing to the barbs and then into the valve Be sure to seat the tubing fully under the pin and all the way to the back of the valve opening 8 After connecting each piece of tubing return to the An...

Page 190: ...nnovOx On Line TOC Analyzer V1 MS rear thru V6 MS V7 MS V6 SH V2 SH V3 SH V1 SH V7 SH V5 SH V4 R V2 R P1 SH Sparger V3 R V6 R Air Purifier optional when installed is located in this area NDIR NDIR Filter V7 R V1 GD Gas Liquid Separator GLS V1 R P1 R V5 R Valves V3 V4 and V5 MS are installed in 5 Stream option only ...

Page 191: ... the sample inlet If additional room is needed for maneuvering first remove the pump head by taking out its two screws 5 Pull open the lever located on the edge of the pump head to release the old tubing 6 Install the new tubing through the pump head as shown 7 Close the pump head lever to secure the tubing 8 Connect the ends of the new tubing as follows P1 SH Pump Head The tubing on top connects ...

Page 192: ...eplacement of the NDIR Filter is indicated when the carrier gas flow rate is too slow and the CO2 peaks are occurring later in the measurement process than is normal If liquid is found in the NDIR sample chamber then the NDIR Filter should be replaced To replace the NDIR filter 1 Shut down the Analyzer via the on screen menu Maintenance Shutdown 2 Wait for the display to turn off and then turn off...

Page 193: ...ack of usage and alert you when consumables are nearing the end of their life To enter consumables installation information 1 Select the Maintenance tab 2 Press the Consumables button 3 Press the Reset Pump or Reset Tubing button for the item you have installed Other Maintenance Tasks Other maintenance tasks are performed only when required and as indicated in this section Sparger Outlet Reactor O...

Page 194: ... Analyzer using a 5 32 in Allen wrench hex key 5 Pull the motor away from the Analyzer Figure 83 The seal is threaded on the motor shaft 6 Remove the seal from the end of the shaft using a 3 8 in wrench Figure 83 and Figure 84 7 Locate the new seal and inspect the valve seating surface Clean the valve seal surface with a paper towel and water if needed 8 Secure the new seal to the end of the valve...

Page 195: ...ve Seal After Removal NOTE Recommended maintenance intervals are for typical applications Particularly harsh applications such as pH 2 high levels of insoluble particles and near saturated brine solutions require more frequent maintenance intervals Contact GE Analytical Instruments Technical Support or a GEAI Applications Engineer for specific details on your application ...

Page 196: ...6 months Exterior sample pump tubing optional equipment 6 months Syringe lubrication 6 months Reactor peristaltic pump tubing 6 months Sample reagent peristaltic pump tubing 6 months Waste tubing 6 months Carrier Gas CO2 Scrubber cartridge optional equipment 6 months High pressure valve seals 7 months High pressure valve seals 8 months High pressure valve seals 9 months Exterior sample pump tubing...

Page 197: ...CO2 Scrubber cartridge optional equipment 18 months High pressure valve seals 19 months High pressure valve seals 20 months High pressure valve seals 21 months Exterior sample pump tubing optional equipment 21 months Syringe lubrication 21 months Norprene Chemical waste tubing 21 months Carrier Gas CO2 Scrubber cartridge optional equipment 21 months High pressure valve seals 22 months High pressur...

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Page 199: ...port in Asia Pacific is available at 65 62674659 or TechSupportSG GEAI ge com In other parts of the world contact your local GE Analytical instruments representative You can also visit the Support tab on our website at www geinstruments com Reviewing Warnings and Errors The Analyzer issues two types of messages Warnings Warnings do NOT stop measurements but may indicate that corrective action is r...

Page 200: ...rt errors and contact GE Analytical Instruments for further instructions and analysis Explanation There are a variety of causes for this error This error should be very rare Analysis of the exported errors will give the specific line of code that triggered the error in order to suggest the resolution 250 Syringe Position Error Message Syringe position error Please power cycle the Analyzer If the p...

Page 201: ...pecific line of code that triggered the error in order to suggest the resolution 6401 Operating System Error Message Operating system error Please power cycle the Analyzer If the problem persists export errors and contact GE Analytical Instruments for further instructions and analysis Explanation This is a catch all for any errors not specifically defined elsewhere These should be very rare and wo...

Page 202: ...ly and model Possible reasons for failure include corrosion on iButton contacts a gap between the iButton and system board contacts or a component failure Consult GE Analytical Instruments for further instructions on determining the root cause 6409 Internal Communications Error Message Internal communications problem Please power cycle the Analyzer If the problem persists consult the Operation and...

Page 203: ...m 6412 Acid Error Message The acid container needs attention Explanation The level sensor in the acid container indicates that the container should be refilled 6413 Oxidizer Error Message The oxidizer container needs attention Explanation The level sensor in the oxidizer container indicates that the container should be refilled 6414 Dilution Water Error Message The dilution water container needs a...

Page 204: ...e cup and the inlet valve if installed is properly adjusted If the problem persists please export the warnings and contact GE Analytical Instruments for further instructions 6420 Stream 5 Flow Warning Message Stream 5 flow stopped Explanation Check that water is flowing in the sample cup and the inlet valve if installed is properly adjusted If the problem persists please export the warnings and co...

Page 205: ...did not cool down in the allotted time 6425 Check Standard Warning Message Check Standard is outside tolerance limits Replace the check standard and repeat the measurement If the warning persists the Analyzer may require calibration Refer to the Operation and Maintenance Manual Explanation The Check Standard solution may have changed concentration the tolerance limits may need to be adjusted or th...

Page 206: ...9 Network Error Message This is an error that occurs when the InnovOx is trying to communicate with a network Shut down the Analyzer turn off the power and reconnect the network cable You may need to contact your IT department for more information If the problem persists please export the errors and contact GE Analytical Instruments for further instructions Explanation An error inside the Analyzer...

Page 207: ...al Instruments for further instructions Explanation The flow rate of gas through the sparger was found to be too low There may be a problem with valve V7 SH or with the gas tubing Check that the correct gas flow is exiting the Gas Supply Module 6434 Carrier Bypass Gas Flow Error Message Go to the Diagnostics screen and run the Gas Valves test V1 R If the gas flow rate fails to maintain 165 cc min ...

Page 208: ...s and diagnostics and contact GE Analytical Instruments for further instructions Explanation Please refer to Printer Setup on page 162 for a list of supported printers 6440 Datastore Manually Archived Message Datastore manually archived by user Historical marker only no follow up necessary Explanation This warning is meant as an historical marker for when a user manually archives the datastore 644...

Page 209: ...inside the optional outer enclosure The sensor is mounted on the lower left inside wall of the outer enclosure and triggers when the face of the sensor contacts fluid Due to variations in installation conditions fluid from leaks may not immediately contact the sensor When a leak is detected the Analyzer reports this error displays a pop up message and stops analysis Do the following 1 Identify and...

Page 210: ...ftware Errors Error Number Description Message Explanation S C Board Bridge Gas Control Sample Handling Reactor NDIR Multi stream I O Board 1 101 201 301 401 501 601 RTOS Error Please power cycle the Analyzer If the problem persists export errors and contact GE Analytical Instruments for further instructions and analysis There are a variety of causes for this error These include timing and softwar...

Page 211: ...cs Side of the Analyzer V1 MS rear thru V6 MS V7 MS V6 SH V2 SH V3 SH V1 SH V7 SH V5 SH V4 R V2 R P1 SH Sparger V3 R V6 R Air Purifier optional when installed is located in this area NDIR NDIR Filter V7 R V1 GD Gas Liquid Separator GLS V1 R P1 R V5 R Valves V3 V4 and V5 MS are installed in 5 Stream option only ...

Page 212: ...8100 09 EN Rev A Chapter 9 Troubleshooting Figure 86 The Electronics Side of the Analyzer Analog I O Board Power Supply Terminator Board NDIR Board Gas Control Module Board Reactor Module Board Sample Handling Module Board Multi stream Module Board ...

Page 213: ...truments 2016 213 of 270 DLM 68100 09 EN Rev A Chapter 9 Troubleshooting Figure 87 Electronics in the Top of the Analyzer Analog I O Board Multi stream Module Board System Controller Board Power Supply Front of Analyzer ...

Page 214: ...GE Analytical Instruments 2016 214 of 270 DLM 68100 09 EN Rev A Chapter 9 Troubleshooting Figure 88 Analyzer Schematic ...

Page 215: ...e Gas Liquid Separator Sample dilution water acid and oxidizer should be drawn into the Analyzer periodically unless either the acid or oxidizer is set to 0 Liquid waste should flow periodically from the Waste outlet Insert the tube from the Waste Gas Liquid Separator port into a flask of water to confirm that gas is flowing Confirm that the Reactor cooling air blows out Reactor Exhaust on the rig...

Page 216: ...is Confirm that the Gas Liquid Separator contains liquid to the proper level Figure 89 and that all tubes are properly connected If maintenance work has recently been performed on the Analyzer confirm that electronics cables are securely attached Figure 89 Connections to the Gas Liquid Separator Reviewing Solutions for Basic Problems If a visual inspection of the Analyzer does not help you identif...

Page 217: ...esentative Figure 90 The Diagnostics Screen When the Diagnostics screen appears Maintenance Diagnostics all of the Analyzer components valves heaters fans pumps etc are in their safe unpowered condition When starting any one of the diagnostic tests only the specific components defined are activated When you press the Cancel or Back button and navigate to the main Diagnostics screen the Analyzer im...

Page 218: ...ntrol Valves Gas Valves and Pneumatic Valves Figure 91 Figure 91 The Valves Screen Flow Control Valves The Flow Control Valve screen contains buttons to test the Multi Stream valves Sample Handler Valves and the Reactor Valves Figure 92 The Flow Control Valve Screen Press the corresponding button to view the detail screen containing buttons for all the valves of that type ...

Page 219: ...e button under the valve name Each valve is open in its active state or closed in its inactive state with the one exception of V6 R which is open in its inactive state Sample Handling Pump P1 SH can also be activated from this screen to aid in troubleshooting flow issues When a valve is working properly you can hear a click when the valve is activated or deactivated You can also feel the click wit...

Page 220: ...en When you press one of the three gas valve buttons a Gas Valve Test begins The button turns to an orange color during the test and the gas flow rate appears to the right of the buttons After the 20 second flow test the Diagnostic Result dialog box with a pass or fail result Figure 95 To stop the Gas Valve Test while it is in progress press the Valve button again or press the Back button Figure 9...

Page 221: ...adjusts to having the valve opened but will stabilize within a few seconds If the flow rate stabilizes to less than 165 cc min investigate possible plugging in the carrier gas lines If the flow rate does not stabilize to 165 cc min after 20 seconds V1 GD may need to be replaced During this test the gas valves are set as follows Reactor Purge Valve V2 R is closed Proportional Valve V1 GD is set to ...

Page 222: ...he appropriate button for the pneumatic valve to test The pneumatic valves are identified with a PV prefix followed by the position number For example PV1 MS refers to the pneumatic valve in position 1 PV2 MS refers to the pneumatic valve in position 2 and so on The state of the valve appears as 1 active or open or 0 inactive or closed on the button under the valve name After pressing a pneumatic ...

Page 223: ...creen with the following criteria The Source Temperature is maintained at 65 o C 2 o C The Detector Temperature is maintained at 55 o C 2 o C Heater The heater test is an examination of the overall reactor heater thermal control system To test the heater temperatures 1 On the Diagnostics screen press the Heater button to display the Heater screen The Heater button is automatically set to Off gray ...

Page 224: ...essage indicating the heater temperature and test results appears the timer resets to zero and the Heater button becomes active again NOTE After the test is started the Heater button becomes inactive to allow the thermal control system to complete its heating and cooling cycle If the Back button is pressed while the heater is heating the fan will not cool it down and the heater will be slow to coo...

Page 225: ... and the Analyzer displays the various Test states Draining Pump P1 R empties any liquid that may be in the sparger through the reactor bypass in preparation for the test Loading The syringe fills with dilution water Dispensing The water dispenses into the sparger Valves V4 R V5 R and V7 R are closed Bypass Flow Valves V3 R and V6 R open and Pump P1 R empties the sparger through the reactor bypass...

Page 226: ...s to help locate leaks in the gas delivery system that may exist in the Analyzer Step by step instructions for each leak test is provided in the following pages Perform the procedures in the following sequential order Check 1 Gas Manifold Leak Check using the Gas Manifold button Check 2 Reactor Inlet Valve Leak Check using the Reactor Inlet Valve button Check 3 Reactor Bypass Leak Check using the ...

Page 227: ... pressure reading at the Pressure Sensor PS4 GS and a timer initially is set to 00 00 min sec appear Figure 100 The Gas Leak Check Screen 4 Press the Gas Manifold button to start the test The Analyzer closes the following valves V1 R V2 R V4 R V5 R and V7 SH The Analyzer opens valves V7 R V6 R and V3 R The Gas Control Module pressurizes the lines for 24 sec and then valve V1 GD closes to trap that...

Page 228: ...check for leaks in the tubing or valves between V1 GD and V1 R V2 R and V7 SH Ensure the brass fittings on the gas manifold in the Gas Control Manifold are not leaking Check gas connections leading to the NDIR end caps If all of those items are correct then contact GE Analytical Instruments for further information 7 To continue the series of gas leak checks leave the plug on the NDIR end cap outle...

Page 229: ...GE Analytical Instruments 2016 229 of 270 DLM 68100 09 EN Rev A Chapter 9 Troubleshooting Figure 101 Gas Manifold Leak Check ...

Page 230: ...r an additional 15 sec If a major leak is detected at this time an Analyzer failed to pressurize warning appears and the test will end During this 39 sec pressurization period the timer remains at 00 00 and Pressurizing appears under the timer 3 When the system passes pressurization the leak check begins the timer starts and Testing appears under the timer The test lasts for 60 sec The test passes...

Page 231: ...GE Analytical Instruments 2016 231 of 270 DLM 68100 09 EN Rev A Chapter 9 Troubleshooting Figure 102 Reactor Inlet Valve Leak Check ...

Page 232: ...sec If a major leak is detected at this time an Analyzer failed to pressurize warning appears and the test will end During this 39 sec pressurization period the timer remains at 00 00 and the analyzer displays Pressurizing under the timer 3 When the system passes pressurization the leak check begins the timer starts and Testing appears under the timer The test lasts for 60 sec The test passes if t...

Page 233: ...GE Analytical Instruments 2016 233 of 270 DLM 68100 09 EN Rev A Chapter 9 Troubleshooting Figure 103 Reactor Bypass Leak Check ...

Page 234: ...this time an Analyzer failed to pressurize warning appears and the test will end During this 39 sec pressurization period the timer remains at 00 00 and the analyzer displays Pressurizing under the timer 3 When the system passes pressurization the leak check begins the timer starts and Testing appears under the timer The test lasts for 60 sec The test passes if the drop in pressure is 2 0 psi 4 If...

Page 235: ...GE Analytical Instruments 2016 235 of 270 DLM 68100 09 EN Rev A Chapter 9 Troubleshooting Figure 104 Reactor Leak Check ...

Page 236: ... system holds for an additional 15 sec If a major leak is detected at this time an Analyzer failed to pressurize warning appears and the test will end During this 39 sec pressurization period the timer remains at 00 00 and Pressurizing appears under the timer 3 When the system passes pressurization the leak check begins the timer starts and Testing appears under the timer The test lasts for 60 sec...

Page 237: ...GE Analytical Instruments 2016 237 of 270 DLM 68100 09 EN Rev A Chapter 9 Troubleshooting Figure 105 Reactor Outlet Valve Check ...

Page 238: ...yzer closes the following valves V1 R V3 R V4 R V5 R V7 R and V7 SH The Analyzer opens valves V2 R and V6 R 5 The Gas Control Module pressurizes the lines for 24 sec and then valve V1 GD closes to trap the pressure in the area being tested and the system holds for an additional 15 sec If a major leak is detected at this time an Analyzer failed to pressurize warning appears and the test will end Du...

Page 239: ...ne of the buttons on the right side of the screen Press one of the 0 mA 4 0 mA or 20 0 mA buttons The ammeter displays the selected current Binary Output The Binary Outputs consist of the Analysis Complete output the System Fault alarm and the four user configurable alarms They can be checked by pressing the Binary Output button on the Diagnostics screen see Figure 90 on page 217 Refer to Tables 3...

Page 240: ...and its float should be moved up and down The screen will indicate the float position by alternating between High Liquid and Low Liquid The level sensors in the sample cups may be accessed by unscrewing the stainless steel cover from the plastic sample cups The level sensors on the Wastewater Sampler are non contact capacitive sensors They can be triggered by grasping the individual sampler tube a...

Page 241: ...or installed in an ATEX enclosure first access the Liquid Sensor Setup screen I O tab Liquid Sensor Setup and temporarily disable the Main Enclosure Leak Sensor button On the Binary Input screen Maintenance tab Diagnostics press the Binary Input button The Auxiliary Enclosure Leak Sensor button appears with either a No Liquid Detected or Liquid Detected state Before continuing with Diagnostics re ...

Page 242: ...he Pumps button The Pumps screen appears Figure 109 The Pumps Screen 2 To test the external pump1 press the External Pump 1 button The pump will start pumping It is normal for the pump to ramp up its speed when the button is pressed to start the test 3 Press the button again to stop the pump The pump will ramp down its speed to stop 4 Repeat steps 2 and 3 to test each pump installed on the Analyze...

Page 243: ...0 2 Press the Mixing bar button to activate the mixing bar in the sparger 3 Press the Mixing bar button again to stop the mixing bar 4 Press the Back button to return the mixing bar to its inactive state Figure 110 Sparger Diagnostics Screen Contacting Technical Support If you need further help troubleshooting any of these or other issues in North America contact GE Analytical Instruments Technica...

Page 244: ... be necessary to return the Analyzer to the factory for repairs Only return the Analyzer if Technical Support has issued you a Return Authorization RA number Several precautions must be followed to ensure that the Analyzer is not damaged during shipment If the original shipping container has not been retained contact GE Analytical Instruments to order shipping supplies In North America contact Tec...

Page 245: ...nalyzer 7 Select the Maintenance tab and press Shutdown 8 When the display is dark turn off the power switch and unplug the conduit 9 Open the door of the Analyzer 10 Wearing eye protection and rubber gloves remove the tubes from the Gas Liquid Separator Unscrew the bracket and remove the Gas Liquid Separator from the Analyzer 11 Drain the Gas Liquid Separator by turning it over It is acceptable f...

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Page 247: ...GE Analytical Instruments 2016 247 of 270 DLM 68100 09 EN Rev A Appendix A Analyzer Dimension Diagrams Diagrams show Analyzer dimensions and required clearances Figure 111 Analyzer Dimensions Front View ...

Page 248: ...GE Analytical Instruments 2016 248 of 270 DLM 68100 09 EN Rev A Figure 112 Analyzer Dimensions Right Side View ...

Page 249: ...GE Analytical Instruments 2016 249 of 270 DLM 68100 09 EN Rev A Figure 113 Analyzer Dimensions Left Side View ...

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Page 251: ...ects the correct Range to use and performs the analysis of the sample using the protocol settings selected by the user For Auto Range to be applied all five Ranges must be calibrated and a calibration for each Range must be assigned to a Calibration Group defined later in this section The Auto range can use default calibrations Auto Restart The Auto Restart feature sets the Analyzer to resume anal...

Page 252: ...The Fail Safe accessory includes level sensors fitted to the Analyzer that trigger an automatic alert when each reagent dilution water and Check Standard carboy should be refilled It also automatically skips analysis of sample streams when flow stops Flush The Sievers InnovOx Online TOC Analyzer can perform two types of flushes Sample Flushes and Dilution Water Flushes defined later in this sectio...

Page 253: ...contribution from this particulate matter will show up in the reported result These events are infrequent and can cause some confusion as to the state of the water system This feature can be enabled or disabled when running in NPOC mode and has a set Outlier Threshold and Reject Outlier value Outlier Threshold This value is utilized in the Outlier Feature When any measurement is greater than the O...

Page 254: ...asurements to be made on a sample Rinse Down This rinse option provides an easy way of rinsing the sample tubing and other Analyzer components after maintenance or after measuring a very high concentration Runtime The time required to analyze the enabled sample streams and Check Standard if enabled Sparge Passing CO2 free gas through the acidified sample removes IC from the solution The subsequent...

Page 255: ...After exporting the data remove the USB drive from the Analyzer and attach it to your computer s USB port It should appear in your available drive list as a removable media drive Export to the Analyzer s Ethernet port and capture the data using a data acquisition program such as PuTTY HyperTerminal and Tera Term See Collecting Historical and Real Time Data on page 159 2 On your computer launch the...

Page 256: ...N Rev A Figure 114 Microsoft Excel Spreadsheet Screen Text Import Wizard Step 1 7 Make sure the Comma check box is selected to identify the file as being comma delimited see Figure 115 Figure 115 Microsoft Excel Spreadsheet Program Text Import Wizard Step 2 ...

Page 257: ...desired you can select a column and assign a Column data format see Figure 116 Click Finish to continue Figure 116 Microsoft Excel Spreadsheet Program Text Import Wizard Step 3 9 A new spreadsheet containing you exported data opens You can now modify the document as you would modify any other Microsoft Excel spreadsheet program file ...

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Page 259: ...r Bit 1 Standby Bit 2 Alarm 1 Bit 3 Alarm 2 Bit 4 Alarm 3 Bit 5 Alarm 4 Bit 6 Coils read State 1 2000 See Footnote 1 Run Bit 0 Stop Bit 1 Check Standard Enabled 2002 See Footnote 2 Stream 1 Enabled 2003 Stream 2 Enabled 2004 Stream 3 Enabled 2005 Stream 4 Enabled 2006 Stream 5 Enabled 2007 Reject Measurement 2008 Coils write Run 5 2000 See Footnote 3 Stop 2001 Check Standard Enabled 2002 ...

Page 260: ...ed Firmware Version Minor 3016 16 bit unsigned Firmware Version Engineering 3017 16 bit unsigned Measurement Mode 3098 16 bit unsigned Current Mode 3099 16 bit unsigned Measurement Time Year 3100 16 bit unsigned Measurement Time Month 3101 16 bit unsigned Measurement Time Day 3102 16 bit unsigned Measurement Time Hour 3103 16 bit unsigned Measurement Time Minute 3104 16 bit unsigned Measurement Ti...

Page 261: ...16 bit unsigned Error Time Second 3206 16 bit unsigned TOC Value Low Word 3300 16 bit unsigned TOC Value High Word 3301 16 bit unsigned TOC Units 3302 16 bit unsigned TOC Stream 3303 16 bit unsigned TC Value Low Word 3310 16 bit unsigned TC Value High Word 3311 16 bit unsigned TC Units 3312 16 bit unsigned TC Stream 3313 16 bit unsigned IC Value Low Word 3320 16 bit unsigned IC Value High Word 332...

Page 262: ...2016 262 of 270 DLM 68100 09 EN Rev A TOC TC IC and NPOC units are Units Value ppt 1 ppb 2 ppm 3 Stream Value Stream 1 1 Stream 2 2 Stream 3 3 Stream 4 4 Stream 5 5 Vial Port 10 Check Standard 20 Value IC 10 TC 20 TOC 30 NPOC 40 ...

Page 263: ...6 263 of 270 DLM 68100 09 EN Rev A Current Mode Value Continuous 0 Grab 1 Autosampler 2 Blank 3 Calibration 4 Verification 5 IC Calibration 6 Mock 7 Online 8 Check Standard 9 Rinse 10 Instrument Model Value Laboratory 10 Online 20 ...

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Page 265: ...er Gas CO2 Scrubber Option 65 Carrier Gas Co2 Scrubber Option 178 196 Check Standard 98 126 134 135 178 Check Standard Measurements Scheduled 135 chloride 67 circuit breaker 73 Clean Inlet 128 138 cleaning gas liquid separator 181 clearances required 247 clock 167 Column data format 257 column data format 257 compressed air 174 175 configuration summary 139 configuring Advanced Setup 165 configuri...

Page 266: ...agram 247 interferences 67 IP address 156 158 159 IP56 65 K Keyboard Options 169 L LCD touchscreen 123 liquid bypass flow 225 liquid reactor flow 226 location of Analyzer 73 165 Luer Lok adapter 89 M Main screen 123 maintenance 178 193 Maintenance Worksheet 196 manual dilution 146 maximum load 80 maximum switching capacity 83 measurement settings 143 Menu screen 125 Modbus 86 160 259 mounting inst...

Page 267: ...bonate 67 sodium hydroxide 67 sparger 136 137 138 146 sparger cleaning the 183 spreadsheet program 255 start analysis 125 streams 132 sulfide 67 summary of confirmation 139 supercritical water oxidation 49 68 system controller board 87 213 system fault alarm 83 86 System Properties 166 system properties 166 system settings 166 T Technical Support 243 terminal blocks 80 terminal ring 72 88 thiosulf...

Page 268: ...GE Analytical Instruments 2016 268 of 270 DLM 68100 09 EN Rev A Index ...

Page 269: ...GE Analytical Instruments 2016270 269 of 270 DLM 68100 09 EN Rev A Notes ...

Page 270: ...GE Analytical Instruments 2016270 270 of 270 DLM 68100 09 EN Rev A Notes ...

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