BA00448C/07/EN/14.

17 Products Solutions Services

71386622

Operating Instructions
TOCII CA72TOC
Analyzer for online determination of TOC in aqueous
media using thermic catalytic combustion
About this document

Warnings
The structure, signal words and color coding applied to safety information comply with the
requirements of ANSI Z535.6 ("Product safety information in product manuals, instructions
and other collateral materials").

Structure of information Meaning

! DANGER This symbol alerts you to a dangerous situation.
Causes (/consequences) Failure to avoid this situation will result in serious or fatal
Consequences of non- injury.
compliance (if applicable)
‣ Corrective action
! WARNING This symbol alerts you to a dangerous situation.
Causes (/consequences) Failure to avoid the situation can result in fatal or serious
Consequences of non- injury.
compliance (if applicable)
‣ Corrective action
! CAUTION This symbol alerts you to a dangerous situation.
Causes (/consequences) Failure to avoid this situation can result in minor or more
Consequences of non- serious injuries.
compliance (if applicable)
‣ Corrective action
NOTICE This symbol alerts you to situations that can result in
Cause/situation damage to property and equipment.
Consequences of non-
compliance (if applicable)
‣ Action/note

Symbols used

Additional information, tip

Permitted or recommended
Forbidden or not recommended

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TOCII CA72TOC

Table of contents
1 Basic safety instructions . . . . . . . . . . . . . 5 6 Commissioning . . . . . . . . . . . . . . . . . . . 35
1.1 Requirements for personnel . . . . . . . . . . . . . . . . . . 5 6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6.2 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3 Workplace safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6.2.1 Commissioning sequence . . . . . . . . . . . . . 35
1.4 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6.2.2 Updating the analyzer software . . . . . . . . 36
1.5 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6.3 Programming mode . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.1 Menu SETTING - RANGE DATA . . . . . . . 38
2 Incoming acceptance and product 6.3.2 Menu SETTING - BASIC DATA . . . . . . . . . 40
6.3.3 Menu SETTING - ALARM LIMITS . . . . . . 41
identification . . . . . . . . . . . . . . . . . . . . . . 7 6.3.4 Menu SETTING - SET CLOCK . . . . . . . . . . 42
2.1 Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . 7 6.3.5 Menu SETTING - SET BRIGHTN./
2.2 Product identification . . . . . . . . . . . . . . . . . . . . . . . . 7 CONTR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6.3.6 Menu SETTING - MEASURING SITE . . . . 43
2.2.2 Identifying the product . . . . . . . . . . . . . . . . 7 6.3.7 Menu LISTS - SHOW COMPLETE
2.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 8 6.3.8 Menu LISTS - ALARM RECORD . . . . . . . . 44
6.3.9 Menu LISTS - MAINTENANCE RECORD . 46
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . 9 6.3.10 Menu LISTS - MIN MAX AVERAGE . . . . 48
6.3.11 Menu LISTS - RECORD ALL DATA . . . . . . 48
3.1 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . 9 6.3.12 Menu TEST - INPUT TEST . . . . . . . . . . . . 50
3.1.1 Methods of installation . . . . . . . . . . . . . . . . 9 6.3.13 Menu TEST - OUTPUT TEST . . . . . . . . . . . 51
3.1.2 Compressed air and water supply . . . . . 11 6.3.14 Two-channel: external changeover . . . . . 52
3.1.3 Gas flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.3.15 Two-channel: time-controlled
3.1.4 Environment . . . . . . . . . . . . . . . . . . . . . . . 11 changeover . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.2 Installation instructions . . . . . . . . . . . . . . . . . . . 12 6.4 Optimizing the analyzer . . . . . . . . . . . . . . . . . . . . . 56
3.2.1 Mounting sequence . . . . . . . . . . . . . . . . . 12 6.4.1 Adjusting the measuring range . . . . . . . . 56
3.2.2 Wall mounting with a pivoting frame . . 12 6.4.2 Influence of dosing volume (pump P2) on
3.2.3 Mounting on a base frame . . . . . . . . . . . 13 the measuring signal . . . . . . . . . . . . . . . . . 56
3.2.4 Mounting the CO2 adsorber . . . . . . . . . . 13 6.4.3 Operating the analyzer with high salt
3.2.5 Connecting the media . . . . . . . . . . . . . . . 14 loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2.6 Preparing the chemicals . . . . . . . . . . . . . 16 6.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3 Post-installation check . . . . . . . . . . . . . . . . . . . . . 20
7 Diagnostics and troubleshooting . . . . 61
4 Electrical connection . . . . . . . . . . . . . . . 21
7.1 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.1 Preparing to wire . . . . . . . . . . . . . . . . . . . 21
4.1.2 Power distribution . . . . . . . . . . . . . . . . . . 22
4.1.3 Signal connection . . . . . . . . . . . . . . . . . . . 24
4.1.4 Power unit . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1.5 Distributor connection . . . . . . . . . . . . . . 27
4.1.6 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Post-connection check . . . . . . . . . . . . . . . . . . . . . 28

5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Operating elements . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Display and keypad . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 Operation during measuring mode . . . . . . . . . . . 32
5.3.1 Recording mode . . . . . . . . . . . . . . . . . . . . 32
5.3.2 Spot view . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.4 Standby mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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TOCII CA72TOC

8 Maintenance . . . . . . . . . . . . . . . . . . . . . .66
8.1 Cleaning the housing . . . . . . . . . . . . . . . . . . . . . . . 70
8.2 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.3 Topping up reagents . . . . . . . . . . . . . . . . . . . . . . . 71
8.4 Replacing the standard . . . . . . . . . . . . . . . . . . . . . 72
8.5 Entering the concentration of the standard
solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.6 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.7 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.7.1 Replacing the hoses on pumps P1 and
P4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.7.2 Changing the hose of pump P2 . . . . . . . . 84
8.7.3 Replacing the hose on pump P3 . . . . . . . 88
8.7.4 Adjusting pump P2 . . . . . . . . . . . . . . . . . . 93
8.7.5 Cleaning dilution water pump P5 . . . . . . 97
8.8 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.8.1 Adjusting the analyzer . . . . . . . . . . . . . . . 98
8.8.2 Calibrating the analyzer . . . . . . . . . . . . . 101
8.8.3 Empty volume dosing . . . . . . . . . . . . . . . 103
8.8.4 Adjustment pH sensor . . . . . . . . . . . . . . 106
8.9 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8.9.1 Screen flush . . . . . . . . . . . . . . . . . . . . . . . 110
8.9.2 Power flush . . . . . . . . . . . . . . . . . . . . . . . 112
8.9.3 Bypass screen . . . . . . . . . . . . . . . . . . . . . . 114
8.9.4 Strip and separation chamber . . . . . . . . 116
8.9.5 Opening the gas circuit . . . . . . . . . . . . . . 120
8.9.6 Combustion pipe . . . . . . . . . . . . . . . . . . . 122
8.9.7 Leakage test . . . . . . . . . . . . . . . . . . . . . . . 129
8.10 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.10.1 Replacing the acid filter . . . . . . . . . . . . . 132
8.10.2 Replacing the gas filter . . . . . . . . . . . . . . 134
8.10.3 Replacing the O2 filter . . . . . . . . . . . . . . 136
8.10.4 Replacing the heated salt trap . . . . . . . . 138
8.10.5 Replacing the filter pads in the
ventilators . . . . . . . . . . . . . . . . . . . . . . . . 142

9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .143
9.1 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9.2 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . 146
9.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

10 Accessories . . . . . . . . . . . . . . . . . . . . . .148

11 Technical data. . . . . . . . . . . . . . . . . . . .149

11.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.2 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.4 Performance characteristics . . . . . . . . . . . . . . . . 150
11.5 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
11.6 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
11.7 Mechanical construction . . . . . . . . . . . . . . . . . . . 150

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . .151

4 Endress+Hauser
TOCII CA72TOC Basic safety instructions

1 Basic safety instructions

1.1 Requirements for personnel

‣ Installation, commissioning, operation and maintenance of the measuring system must
be carried out exclusively by specially trained technical personnel.
‣ The technical personnel must be authorized for the specified activities by the system
operator.
‣ The electrical connection may only be established by an electrical technician.
‣ The technical personnel must have read and understood these Operating Instructions
and must adhere to them.
‣ Faults at the measuring point may only be rectified by authorized and specially trained
personnel.
Repairs not described in the enclosed Operating Instructions may only be carried out at
the manufacturer’s premises or by the Service Organization.

1.2 Designated use

The analyzer is a compact thermo-catalytic analytical measurement system. It is designed to
monitor the TOC content of industrial and municipal wastewater.
The device is particularly suitable for the following applications:
• Monitoring of industrial wastewater, in the inlet and outlet
• Control of process wastewater
• Monitoring of surface run-off in industrial systems
• Monitoring of surface run-off in airports
• Municipal wastewater monitoring
• Recording the carbon load for nutrient dosing
Any other use than the one described here compromises the safety of people and the entire
measuring system and is therefore not permitted.
The manufacturer is not liable for damage resulting from incorrect or non-designated use.
NOTICE
Applications which do not comply with specifications
Possibility of incorrect measurements and faults, including failure of the measuring point
‣ Only use the product in line with the product specifications.
‣ Pay particular attention to the technical data on the nameplate.

1.3 Workplace safety

As the user, you are responsible for complying with the following safety conditions:
• Installation specifications
• Local standards and regulations

1.4 Operational safety

‣ Before commissioning the entire measuring point, check all the connections. Ensure that
the electrical cables and hose connections are not damaged.
‣ Do not operate damaged products, and secure them against unintentional
commissioning. Mark the damaged product as being defective.
‣ If faults cannot be rectified, you must take the products out of service and secure them
against unintentional commissioning.
‣ Do not touch any rotating pump parts.

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Basic safety instructions TOCII CA72TOC

1.5 Product safety

The product is designed to meet state-of-the-art safety requirements, has been tested and
left the factory in a condition in which it is safe to operate.
The relevant regulations and standards have been met.

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TOCII CA72TOC Incoming acceptance and product identification

2 Incoming acceptance and product

identification

2.1 Incoming acceptance

• Make sure the packaging is not damaged!
• Notify your supplier of any damage to the packaging. Keep the damaged packaging until
the matter has been settled.
• Make sure the contents are not damaged!
• Notify your supplier of any damage to the delivery contents. Keep the damaged goods until
the matter has been settled.
• Check that the delivery is complete and nothing is missing. Check it against the delivery
papers and your order.
• Pack the product for storage and transportation so that it is reliably protected against
impact and moisture. The original packaging offers the best protection. In addition, the
permitted ambient conditions must be observed (see Technical data).
• If you have any questions, please contact your supplier or your local sales center.

2.2 Product identification

2.2.1 Nameplate
The nameplate bears the following information:
• Manufacturer details
• Order code (device version)
• Serial number
• Measuring range
• Outputs and communication
• Power supply
• Degree of protection
• (Permitted) ambient conditions
Compare the data on the nameplate with your order.

2.2.2 Identifying the product

To establish your product version, enter the order code from the nameplate into the
search field at the following address:
www.products.endress.com/order-ident

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Incoming acceptance and product identification TOCII CA72TOC

2.3 Scope of delivery

The delivery includes:
• 1 CA72TOC analyzer
• Accessories for leak check
• Tool kit to remove the glass ball and the media
• Accessories for acid filter
• Kit for commissioning of stripper and separation chamber
• Accessories for combustion furnace maintenance
• Hose kit
• 1 canister, 5 liter
• 2 canisters, 2 liter
• Set of cabinet keys
• EMC junction box
• 10 ml graduated cylinder
• Sponge cloth
• Protective goggles
• Gloves, acid-proof and base-proof
• Protective gloves, heat-resistant
• Silicone grease
• Operating Instructions, English
If you have any questions, please contact your supplier or your local sales center.

2.4 Certificates and approvals

Declaration of Conformity
The product meets the requirements of the harmonized European standards.
It thus complies with the legal requirements of the EC directives.
The manufacturer confirms successful testing of the product by affixing the 4 mark.
CSA C/US General Purpose (optional)
The device meets the requirements of "Class 8721 06, laboratory equipment, electrical; Class
8721 86, electrical equipment for laboratory use - certified to US standards" for indoor use.
Certificate no.: 2577401
Electrical safety
In compliance with IEC 61010-1, protection class I, Installation category II.
Fluctuations in the supply voltage may not exceed 10 percent of the nominal voltage.

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TOCII CA72TOC Installation

3 Installation

3.1 Installation conditions

3.1.1 Methods of installation

The analyzer can be mounted in three ways:
• As a standalone desktop unit
• Mounted to the wall (option F1)
• Mounted on a base frame (option F2)

a0023087

Fig. 1: Dimensions in mm (in)

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Installation TOCII CA72TOC

894 (35.2)

(4.41)
600 (23.6)

112
1558 (61.3)

a0023087

Fig. 2: Dimensions in mm (in)

Mount the device in such a way that it can also be accessed from the rear for
maintenance purposes.

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TOCII CA72TOC Installation

3.1.2 Compressed air and water supply

When operating the analyzer, use only CO2-free air.
The air must be dry and oil-free and must meet the following conditions:
• < 3 ppm CO2
• < 3 ppm hydrocarbons
• The pressure must be 2 bar (29 psi) constantly.
• The pressure tolerance is ±5 %.
• The required quantity of compressed air is:
– 600 l/h (21.2 ft3/hr) for the CO2 adsorber gas generator (Domnick Hunter)
– 60 l/h (2.12 ft3/hr) for the soda-lime CO2 scrubbers
• The compressed air supply must be fitted with a CO2 scrubber (inlet pressure 4 to 10 bar
(58 to 145 psi) and a pressure regulator.
• Connection: 4/6 mm DN

A water connection is absolutely essential for the correct operation of the CA72TOC
analyzer.

The water is connected via a 6/8 mm DN or G3/8 coupling. The pressure must be between
2 and 4 bar (29 to 58 psi) (for version with "sample predilution": 3 ±0.2 bar (43.5 ±3 psi)).
In the version with sample predilution, use de-ionized water (DI water) or drinking
water with a water hardness level < 10 °dH (< 179 ppm CaCO3) for the dilution water.

3.1.3 Gas flow

When operating the analyzer, use only CO2-free air. Primary pressure at the
manometer: 2 bar (29 psi).

Circuit gas
The flowmeter for the circuit gas is used to perform function checks and is set at the factory.
The flow rate during operation is 0.7 to 1.2 l/min (1.5 to 2.5 ft3/hr).

Carrier gas
The volume flow for the carrier gas is regulated using a precision restrictor. The flow is
approx. 0.8 l/min (1.7 ft3/hr) at a pressure of 2 bar (29 psi).

Stripping gas
The volume flow for the stripping gas is also regulated using a precision restrictor. The flow
is approx. 0.15 l/min (0.3 ft3/hr) at a pressure of 2 bar (29 psi).

3.1.4 Environment
• The analyzer requires a drain beneath the device. Use a 6/8 mm drain pipe made of PTFE.
No backpressure should form in the drain.
• An exhaust gas connection is required in enclosed spaces. Halogens or other vapors may
not build up in this area. No backpressure should form in the 4/6 mm exhaust gas tube.
• Ambient temperature range: 5 to 35 °C (41 to 95 °F)
• Humidity: 20 to 80 %, non-condensating
• Pollution degree 2
• The analyzer must be accessible from the front and rear.
•  2000 m (6500 ft) above sea level
• No direct sunlight

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Installation TOCII CA72TOC

3.2 Installation instructions

! WARNING
Danger! Risk of electric shock!
‣ Do not connect the analyzer to the power grid before all the installation work has been
completed and the liquid and gas media are connected.
‣ To connect the analyzer to the electricity supply, follow the instructions in the "Electrical
connection" section.

3.2.1 Mounting sequence

1. Mount the analyzer on the base frame, on a table or in the pivoting frame.
2. Mount the EMC junction box (right-hand side of device).
3. Mount the reagent tray under the analyzer.
4. Mount the vent on the sample conditioning system (only for PA-2 / PA-3 or PA-9).
5. Connect the media (see the "Connecting the media" section).
6. Establish the electrical connections (see the "Wiring" section).

3.2.2 Wall mounting with a pivoting frame

In the "Wall-mount" version, the analyzer is mounted to the wall with a pivoting frame.

a0014227

Fig. 3: Pivoting frame for wall mounting, dimensions in mm (in)

All bore holes for wall-mounting have a diameter of 8.5 mm (0.33").

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TOCII CA72TOC Installation

3.2.3 Mounting on a base frame

In the "Base frame" version, the analyzer is mounted on a base frame.

Mount the device in such a way that it can also be accessed from the rear for
maintenance purposes.

62
.4) 0(
24 24
0( .4)
62

812 (32.0)

mm (inch)

a0013913

Fig. 4: Mounting on a base frame

3.2.4 Mounting the CO2 adsorber

CO2-free air can be provided in one of two ways:
• With a gas generator
• With a soda-lime scrubber

Depending on the version ordered:

• Position the CO2 adsorber gas generator (cartridge gas generator) on the ground or mount
it on the wall in accordance with the enclosed drawing, or
• Mount the soda-lime CO2 scrubber in accordance with the enclosed Operating Instructions
BA01243C/07/EN

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Installation TOCII CA72TOC

3.2.5 Connecting the media

12

11
4
10
9
5

6 8
7

a0012643

Fig. 5: Connections on the left side panel

1 Power cable
2 Gas outlet
3 Gas connection
4 Water connection
5 Bypass rinse water
6 External grounding
7 Standard C2 connection
8 Standard C1 connection
9 Acid connection
10 Condensate drainage
11 Sample supply
12 Sample drainage

14 Endress+Hauser
TOCII CA72TOC Installation

Sample supply
Sample is supplied via a 3/8" connection on the left side panel (item 11).

Sample conditioning Inlet connection (mm / in) Drain connection (mm / in)
Outer diameter Outer diameter

PA2 40 / 1.57 50 / 1.97

PA3 20 / 0.79 30 / 1.18

PA9 20 / 0.79 32 / 1.26

Analyzer sample drainage

Sample is drained off unpressurized via a DN 6/8 mm hose connection (compression fitting)
on the left side panel (item 12) into an open channel or pipe. Route the hose in such a way
that backpressure cannot form.

Condensate drainage
Condensate is drained off without pressure via a hose gland (PE, DN 1.6/3.2 mm, scope of
delivery) on the left side panel (item 10):
• into a collecting vessel,
• into an open channel or
• into a pipe.
The condensate discharge is acidic (pH value = 2 to 2.5).
Route the hose in such a way that backpressure cannot form.

Acid connection
Place the acid cistern in the reagent tray. Connect the acid hose to the left side panel
(item 9).

Connecting the standards

Put the standard containers in the holders on the left side panel.
Connect the standards to the left side panel (C1 to item 8 and C2 to item 7).

Gas outlet
Gas escapes via a hose gland (DN 4/6 mm) on the left side panel (item 2). Ensure that there
is adequate ventilation in the room, or remove the exhaust gas from the room via a hose
(DN 4/6 mm). The end of the hose must be positioned in such a way that it is not under
pressure and is protected from frost.

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Installation TOCII CA72TOC

3.2.6 Preparing the chemicals

! WARNING
Accidents with chemicals can kill, blind, burn, or damage lungs.
Many chemicals are toxic or corrosive, and some are explosive - either on their own or
combined with other substances. Others are hazardous because they can be absorbed easily
through the skin or respiratory system.
‣ Therefore, when working with chemicals always follow the precautionary measures
outlined in the "Precautionary measures when working with chemicals" section.
‣ Observe the warnings on the safety data sheets.
The analyzer requires the following chemical solutions:
• Stripper solution
Nitric acid HNO3 (CAS: 7697-37-2) conc. 25 %
Once it has been diluted accordingly, this acid is used to acidify the sample. This converts
the carbonate ion CO32- into CO2 and removes the dissolved CO2 from the solution
(TIC stripping).
• Parent solution
Potassium hydrogen phthalate (KHP (CAS: 877-24-7)) with a concentration of
5 000 mg TOC/l
This parent solution for calibrating and adjusting the analyzer is used as a diluted standard
in the measuring range from 0 to 600 mg TOC/l. In the event of high KHP concentrations
and sample acidification (pH < 2.5), there is the risk of KHP precipitating in the solution.
• Parent solution
Citric acid (CAS: 5949-29-1) with a concentration of 100 000 mg TOC/l
This parent solution for calibrating and adjusting the analyzer is used as a diluted standard
in the measuring range from 600 mg TOC/l onwards.
The stripper solution and the parent solutions are available from Endress+Hauser (see
"Accessories" chapter).

Specifying the standard concentrations

The right choice of standard concentration is key to the accuracy of the measurement
method.
Before specifying the concentrations of the standard solutions, determine the concentration
range in which the device is expected to measure. The most common concentrations should
be covered by the standard solutions.
Please note, however, that there should be a concentration ratio of between 1:4 and 1:20
between the two standard solutions.
If a limit value is to be monitored, it makes sense for the concentration of a standard to
correspond to the concentration of the limit value, as this guarantees the greatest precision
when monitoring.

Please note that there is no method of TOC measurement that can provide accurate
measurement results over a span greater than 1:30.

Example:

Concentration to be measured: 3 to 300 mg/l

Most frequent concentration: 50 to 150 mg/l
Limit value to be monitored: 200 mg/l

20 and 200 mg/l should be selected here as the standard solutions. The system can then
measure accurately in the range from 10 to 300 mg/l (taking the measuring range of the
system into account). A higher measured value deviation can be expected below a
concentration level of 10 mg/l and above a concentration level of 300 mg/l.

16 Endress+Hauser
TOCII CA72TOC Installation

Precautionary measures when working with chemicals

• Carefully read the "Material Safety Data Sheet" (MSDS) that is supplied with every chemical
to determine the hazards posed and what precautionary measures have to be taken. If you
are not sure what risks are associated with the chemical, please ask appropriately qualified
experts.
• Never prepare chemicals on your own. You may need assistance in the event of an
accident. For this reason, always make sure that someone is close-by. Only prepare
chemicals in a properly equipped laboratory.
• When preparing chemicals always wear protective goggles, rubber gloves and a rubber
apron. In addition, wear a dust mask or face shield when working with fine-powder
chemicals.
• Chemicals or solutions that are used with the analyzer (or another process analysis device)
should never be inhaled, tasted or swallowed.
• When preparing solutions, you must always label the containers appropriately, indicating
the contents and the date of preparation. Dispose of unlabeled or expired solutions in
accordance with local regulations and guidelines.
• Some chemicals are very reactive when combined with other substances or dissolved in
water. Avoid the risk of dangerous accidents occurring: If you do not know how certain
chemicals react, make sure you do not mix them with other substances. Never mix
chemicals that are known to react severely.

Reagent quality
Reagent quality can affect the accuracy of measurements. Only use high-quality
reagents. For this reason, follow the steps outlined below to ensure reagent quality.
• For 10, 100, and 500 mg/l units, use the best grade of reagents. Ordinary commercial-
grade reagents are suitable for standard solutions with concentrations of 1,000, 5,000
and 10,000 mg/l. For the KHP calibration standard, use reagent grade or better for all
units.
• Rinse all glassware and plastic containers thoroughly with deionized water. To achieve the
best results, we recommend washing them once more with acid before use and rinsing
them thoroughly with deionized water.
• Weigh the calibration solution as accurately as possible prior to mixing. Keep the
containers closed to avoid contamination and a deterioration in quality.
• Accurate preparation of the calibration standard is essential for accurate calibration of the
analyzer. Inaccurate preparation of the calibration standard will result in a faulty
calibration, which in turn will yield incorrect results.

Preparing the parent solution using potassium hydrogen phthalate

! CAUTION
Potassium hydrogen phthalate (KHP) can irritate the skin and cause problems with the
eyes or respiratory channel.
‣ Do not inhale the powder and do not attempt to ever swallow any of the solution
prepared.
‣ Observe the warnings on the safety data sheets.
Shelf life: Storable parent solutions with concentrations of 5,000 mg/l are stable for 12
months if stored in a cool, dark place at 4 to 8 °C (40 to 46 °F). Prepared standard solutions
must be used within four weeks even if stored in a cool, dark place.

Concentrations: depends on the application.

Endress+Hauser 17
Installation TOCII CA72TOC

Procedure:
For an organic carbon solution with a concentration of 5,000 mg/l, use a 1-liter volumetric
flask to dissolve 10,627 g of p.a. KHP in 500 - 700 ml deionized water (other concentrations
of the solution can be found in the following table). Once the chemical has dissolved, fill the
volumetric flask up to the mark. Stir the solution once more. Label the container, indicating
the contents and the date of preparation.

mg/l carbon g KHP Volume

5,000 10.627 1l

1,000 2.1254 1l

500 1.0627 1l

100 0.21254 1l

10 0.021254 1l

The solution with a concentration of 5,000 mg/l is stable (particularly when stored in a cool,
dark place). It is recommended to perform serial dilutions on the basis of a standard
substance of 5,000 mg/l to reduce the concentrations if needed. Example:
• If 10 ml of a solution with a concentration of 5,000 mg/l is diluted with 90 ml deionized
water, this results in a concentration of 500 mg/l.
• If 10 ml of a solution with a concentration of 500 mg/l is diluted with 90 ml deionized
water, this results in a concentration of 50 mg/l.
• If 10 ml of a solution with a concentration of 50 mg/l is diluted with 90 ml deionized
water, this results in a concentration of 5 mg/l.
Serial dilution is the preferred method for creating lower concentrations. This is instead of
diluting 1 ml of the 5,000 mg/l solution with 99 ml deionized water. The latter method can
result in measurement errors.
NOTICE
Please note the following:
‣ Storable parent solutions with concentrations of 1,000 and 5,000 mg/l are stable for
several weeks at room temperatures. Parent solutions must be stored in cool dark place.
‣ In the case of a solution with a concentration of 10 mg/l, on the other hand, the quality
starts to deteriorate at room temperature within 3 to 5 days. For improved stabilization
of KHP standard solutions, nitric acid or sulfuric acid can be used for acidification
purposes. Use 4 ml of the 25% nitric acid (HNO3) or 4 ml of the 20% sulfuric acid (H2SO4)
per liter.
‣ If parent solutions with a high KHP content acidify, there is the risk of the KHP
precipitating.
‣ Make sure to keep the container with the crystalline KHP sealed at all times. If the
crystalline KHP comes into contact with the air, it absorbs water very quickly and must be
dried before use. Otherwise you will get inaccurate measurements since the
concentration of carbon is lower in the hydrous salt. KHP that has come into contact with
air must be dried for one hour at 105 °C (221 °F).

18 Endress+Hauser
TOCII CA72TOC Installation

Preparing the parent solution from citric acid

! WARNING
Nitric acid is highly caustic. Citric acid can irritate the skin and eyes and cause
respiratory problems.
‣ Wear protective goggles, gloves and protective clothing.
‣ Always add acids to water, not vice versa.
‣ Never attempt to swallow any of the solution prepared.
‣ Observe the warnings on the safety data sheets.
Shelf life: Storable parent solutions with concentrations of 100,000 mg/l are stable for
12 months if stored in a cool, dark place at 4 to 8 °C (40 to 46 °F). Prepared standard
solutions must be used within four weeks even if stored in a cool, dark place.

Material:
• 1-liter volumetric flask
• Citric acid monohydrate C6H8O7 · H2O (purity: p.a.)
• Nitric acid HNO3 (65 %, purity: p.a.)
Procedure:
For an organic carbon solution with a concentration of 100,000 mg/l, dissolve 291.6 g of
citric acid monohydrate in 500 ml of deionized water in a 1-liter volumetric flask (other
concentrations of the solution are listed in the table below). Carefully add 55.0 ml (77.0 g)
of nitric acid. Once the chemicals have dissolved, top up the mixture with water until the
1-liter mark is reached. Stir the solution once more. Label the container, indicating the
contents and the date of preparation.

mg/l carbon Citric acid in g Nitric acid in ml Volume

100,000 291.6 55.0 1l

50,000 145.8 55.0 1l

10,000 29.16 55.0 1l

The solution with a concentration of 100,000 mg/l is stable (particularly when refrigerated).
It is recommended to perform serial dilutions on the basis of a standard substance of
100,000 mg/l to reduce the concentrations if needed. Example:
• If 10 ml of a solution with a concentration of 100,000 mg/l is diluted with 90 ml deionized
water, this results in a concentration of 10,000 mg/l.
• If 10 ml of a solution with a concentration of 10,000 mg/l is diluted with 90 ml deionized
water, this results in a concentration of 1,000 mg/l.
• If 10 ml of a solution with a concentration of 1,000 mg/l is diluted with 90 ml deionized
water, this results in a concentration of 100 mg/l.
Serial dilution is the preferred method for creating lower concentrations. This is instead of
diluting 1 ml of the 100,000 mg/l solution with 99 ml deionized water. The latter method
can result in measurement errors.

Preparing the stripping reagent

Stripping reagent dosing is regulated via the pH sensor. The regulation range for dosing is
approx. 300 times the minimum feed rate of the acid pump. The necessary acid quantity
varies greatly from measuring place to measuring place. Ideally, the strength of the acid in
the feeder tank should be set in such a way that the system can regulate in both directions,
but the regulation range should be higher for higher volumes of acid dosed.

Endress+Hauser 19
Installation TOCII CA72TOC

Regulation aid:
The concentration of the acid is typically in the region of 5 to 10 %. The aim should be to
achieve a feed rate of 2 to 5 % (17 μl/min to 44 μl/min) for pump P3 (the current feed rate
can be read in the PROGRAMMING/TEST/OUTPUT/PUMPS menu).
For the acid feeder, mix 0.5 l deionized (DI) water with 0.125 l HNO3 25 % HNO3.
• Fill the acid hose
• Start measuring operation with a real sample
• Allow the acid dosing system to regulate
• Feed rate > 2 % < 5 %, note the acid concentration and use for future mixtures
• Feed rate < 2 % acid concentration, dilute preparation
• Feed rate > 5 % acid concentration, increase the concentration of the preparation
• Replace the contents of the acid hose
• Allow the acid dosing system to regulate, read off the feed rate

Deionized water (ml) HNO3 25 % (ml) HNO3 concentration

Increase concentration 500 + 125 5.0 %

+ 125 8.3 %
+ 125 10.7 %

+125 12.5 %

Dilute 500 +125 5.0 %

+ 500 2.8 %
+1000 1.5 %

+2000 0.8 %

Using other acids

• Nitric acid
Nitric acid does not form lyophobic salts in the strip chamber. The resulting nitrogen
oxides in the combustion gas are filtered out with an acid filter upstream from the
IR detector.
• Phosphoric acid
Phosphoric acid is a low-volatility, odorless acid that generates practically no precipitate.
Following combustion, substances are formed that are filtered out completely in the
heated salt trap.
• Sulfuric acid
Sulfuric acid is a low-volatility, odorless acid. When using sulfuric acid, precipitate can be
expected with alkaline earth metal ions. In addition to the sulfur dioxides, salts are
generated as a reaction product downstream from the furnace. These salts are easily
removed in the heated salt trap. Gypsum can also occur if the water is very hard.
• Hydrochloric acid
Hydrochloric acid is a volatile acid with a pungent odor. Salts do not precipitate in the strip
chamber. During combustion, salts occur (heatable salt trap) as does HCl gas, which is
absorbed in the condensate.

3.3 Post-installation check

• After the installation, make sure that all connections are secure and that there are no
leaks.
• Check all hoses for damage.

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4 Electrical connection

4.1 Wiring
! WARNING
The device is live!
Incorrect wiring can result in injury or a fatality
‣ The electrical connection may only be established by an electrical technician.
‣ The electrical technician must have read and understood the instructions in this manual
and must adhere to them.
‣ Prior to commencing work on the connections, ensure that no voltage is applied to any
of the cables.

4.1.1 Preparing to wire

! WARNING
Danger! Risk of electric shock!
‣ Disconnect the device from the power supply system (disconnect the mains plug). The
line filter, the overvoltage module and the main switch are still connected to the power
supply even when the main switch is switched off.
‣ Before connecting the device, make sure that the line voltage matches the voltage
indicated on the nameplate.
‣ Ensure that the analyzer is sufficiently grounded via the mains connection.
The analyzer is available for the following line voltages:
• 115 V AC 50 Hz
• 115 V AC 60 Hz
• 230 V AC 50 Hz
• 230 V AC 60 Hz
The following condition must be met when grounding the analyzer via the mains
connection:
50 V < R · Imax
Imax = maximum current at which the residual current circuit breaker is not yet triggered.
R = the resistance between protective ground and device ground.
If this condition cannot be guaranteed, the device must be grounded on site.
You must make the following connections:
• Alternating current connection via mains plug
• External grounding if necessary
• Analog 0/4 to 20 mA outputs
• Binary outputs
• Binary inputs
• RS-232
The signal connections are located in the EMC screening box on the right-hand side of the
cabinet.
The connection for the external ground is located at the bottom on the left-hand side of the
cabinet.

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Electrical connection TOCII CA72TOC

4.1.2 Power distribution

a0025863

Fig. 6: Power distribution wiring diagram

22 Endress+Hauser
TOCII CA72TOC Electrical connection

Terminal strip assignment:

Connection Description

3 Main switch, power distribution

4 Solenoid valve 3 - stripping gas

6 Peltier cooler regulator

7 Membrane compressor

8 Tube furnace

9 External salt trap

10 Solenoid valve 4, standard 1 + 2

11 Solenoid valve 7, carrier gas

13 Solenoid valve 5, bypass screen rinsing

14 Solenoid valve 1, sample/standard

15 Solenoid valve 6, channel 1/channel 2 (optional)

16 24 V power supply

17 Solenoid valve 2, strip chamber

18 Solenoid valve 8, dosing

Relay module assignment:

Relay No. Relay type Function

1 4A Solenoid valve 1, sample/standard

2 3A Solenoid valve 2, strip chamber rinsing

3 25A Solenoid valve 3 stripping gas, tube furnace regulator, external salt trap
regulator, Peltier cooler regulator, membrane compressor

4 4A Solenoid valve 4, standard 1 + 2

5 4A Solenoid valve 5, bypass flush

6 4A Solenoid valve 6 channel 1 / 2

7 4A Solenoid valve 7, carrier gas

8 3A Solenoid valve 8, dosing

RA 25A Emergency shutdown

RB 25A Heating regulator furnace

RC 25A Heating salt trap

The power distribution is located at the back in the top door.

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Electrical connection TOCII CA72TOC

4.1.3 Signal connection

1 1 +24VDC
1 GND

I
2 2
1 +24VDC
1
2
2 GND

II
2 1 +24VDC
1 3 GND

binary out
2

III
2 1 +24VDC
4

binary in
1 2 GND

IV
2 1 +24VDC
2 5 GND
1 +24VDC
0/4-20 +
2 6 GND
40
mA - 1 +24VDC
2 7 GND
0/4-20 +
41 1 +24VDC
mA -
8 GND
2

RS 232

a0011911

Fig. 7: Signal connection

I Alert 1 Calibration, external activation

II Alarm for limits 2 Adjustment, external activation
III Standby 3 Screen flush, external activation
IV Operating control 4 Power flush, external activation
40 Signal output channel 1 5 Not assigned
41 Signal output channel 2 (optional) 6 Not assigned
7 Standby, external activation
8 Channel switchover, external activation
(optional)

Messages I to IV Potential-free relay contact (max. 0.2 A and 50 V), normally

closed (NC)
Relay contact I closed = no fault messages
Relay contact II closed = no collective alarm
Relay contact III closed = standby
Relay contact IV closed = operating check
At the end of a measuring cycle, relay IV opens for 2 seconds to
signal the end of the measuring cycle.

Signal outputs 0 to 20 mA or 4 to 20 mA can be switched, galvanically

40 to 41 isolated, max. load 500 

Signal inputs 1 to 8 24 V DC active, max. load 500 

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TOCII CA72TOC Electrical connection

Signal Description Switch status off Switch status on

input (open) (closed)

1 Calibration, external activation Analyzer is in measuring Calibration is triggered

mode

2 Adjustment, external activation Analyzer is in measuring Adjustment is triggered

mode

3 Screen flush, external activation Analyzer is in measuring Screen flush is triggered

mode

4 Power flush, external activation Analyzer is in measuring Power flush is triggered

mode

5 Not assigned

6 Not assigned

7 Standby, external activation Analyzer quits standby Standby is triggered.

mode and returns to Analyzer is prepared for
measuring mode or is in standby. Standby is
measuring mode. maintained as long as the
switch status is closed.

8 Channel switchover, external Analyzer is in measuring Channel switch is

activation (optional) mode for the selected performed.
channel.

The potential-free contact must be closed for approx. 2 seconds to allow the switch
status to be triggered.
TOCII CA72TOC is suitable for connection to industrial power supply systems in
accordance with EN 61326-1, Class A.

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Electrical connection TOCII CA72TOC

4.1.4 Power unit

24V +- 23A
24V +- 23
24V +- 21
24V +- 20
T
+ 22
-

a0011956

Fig. 8: Power unit assignment

Power unit wiring arrangement:

Connection Description

20 Pump control 24 V DC

21 Magnetic stirrer control 24 V DC

22 Motor

23 Relay module 24 V DC

23A Ventilator 24 V DC

The connections for the power unit are located on the rear side of the computer.

26 Endress+Hauser
TOCII CA72TOC Electrical connection

4.1.5 Distributor connection

a0021331

Fig. 9: Distributor (* = Pin 1 at MI1 - MI4 and at PWM)

Distributor assignment:

Connection Description
FI-24 NDIR detector

FI-26 pH - amplifier

BI-28 Carrier gas pressure switch DI 06

BI-29 Leak detector DI 05

BI-30 Standby internal DI 04

BI-34 Peltier cooler regulator DI 01 + 02

BI-35 Pressure switch dilution water DI 03

PWM-1 Furnace regulator (pin 1 black, pin 2 blue)

PWM-2 Salt trap regulator (pin 3 brown, pin 4 gray)

BO-39 Relay module

Pu-38 Pump control

Ext. 55 External connection socket

MI1 Temperature sensor, furnace regulator, type K (pin 4 green, pin 6 white)

MI2 Temperature sensor, furnace regulator type K (pin 4 green, pin 6 white)

MI3 Temperature sensor, salt trap regulator, type J (pin 4 black, pin 6 white)

MI4 Pressure sensor (pin 1 VS brown, pin 3 signal + black, pin 4 signal – gray, pin 6 GND blue)

4.1.6 Fuses

Assembly Fuses

Power distribution 2.5 A, slow-blow, design: fine-wire fuse 6.3 x 32

Relay 4 A per relay, slow-blow, design: TR5

Power unit 2 A, slow-blow, design: fine-wire fuse 5 x 20

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Electrical connection TOCII CA72TOC

4.2 Post-connection check

Carry out the following checks after electrical connection:

Device status and specifications Note

Is the exterior of the analyzer or cable undamaged? Visual inspection

Electrical connection Note

Does the supply voltage correspond to the data on the 230 V AC 50/60 Hz
nameplate? 115 V AC 50/60 Hz

Are current outputs shielded and connected?

Are the mounted cables strain-relieved?

Are the cable types properly separated? Run power supply and signal lines
separately over the entire travel
distance. Separate cable channels are
ideal.

Are the cables routed without loops or crossovers?

Are power supply and signal lines connected correctly according to

wiring diagram?

Are all screw terminals tightened?

Are all cable entries mounted, tightened and leak-resistant?

28 Endress+Hauser
TOCII CA72TOC Operation

5 Operation

5.1 Operating elements

a0011861

Fig. 10: Display and operating elements

1 Main switch 16 Heated salt trap (optional)
2 Display and operating elements 17 Circuit gas flowmeter
3 USB connection 18 Dilution water pump P5 (optional)
4 Pump P2 sample analysis 19 Acid hose connector
5 Junction box 20 MV4 calibration standard changeover C1/C2
6 Compressor switch 21 MV1 wastewater/calibration standard
7 Ventilator changeover
8 Separation chamber 22 Valve for online sample/manual sample
9 Dosing valve 23 Pump P3, acid dosing
10 Ventilator 24 Pump P4, sample - dilution (optional)
11 Injection unit 25 Mixing chamber (optional)
12 Acid filter 26 Pump P1, sample - strip chamber/condensate
13 Tube furnace with catalyst extraction
14 Air outlet (filter pad) 27 Condensate hose connector
15 Combined filter (water trap) 28 Strip chamber with pH electrode
29 Sample conditioning

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Operation TOCII CA72TOC

5.2 Display and keypad

1 2 3

9 8
a0007996

Fig. 11: Display and operating elements

1 Screen, 16 lines with 40 characters per line
2 Keyboard
3 Arrow keys (cursor)
4 Function key "Measuring"
5 Function key "Service"
6 Function key "Programming"
7 Function key "Help"
8 Key "Enter"
9 Key "CLR"

"Operation" key
Pressing the "Operation key" takes you back to the measuring mode.
The display shows the measured value trend of the last six hours in
graphic form.
"Service" key
Pressing the "Service key" takes you to the maintenance mode.
The menu contains the following items:
• Pumps
• Calibration
• Cleaning
• Filter
"Programming" key
Once you have pressed the "Programming key" and entered the four-digit
code (see code card supplied), you will be taken to the programming
menu.
The menu contains the following items:
• Setting
You can configure the measuring device here.
• Lists
You can visualize the reports and alarm messages on the display here.
• Test
You can use test programs to test the functions of the device here.
Use the help key [?] to obtain additional information on the current
date and the program version.
Arrow keys
The arrow keys help you position the cursor on the screen.
The "right" arrow key allows you enter negative values for certain
parameters. A minus sign appears once this key has been pressed.

30 Endress+Hauser
TOCII CA72TOC Operation

"Enter" key
The "Enter key" has the following functions:
• You launch a menu item.
• You start a program item.
• You always confirm an entry with the "Enter key".
• When performing maintenance and service tasks, you confirm each
step with the "Enter key" on completion of the step.
"?" key
A short help text on the program item appears when you press the
"? key".
Press the "? key" a second time to exit the help text.
"4" key
Calls up the limit value list.
The current limit value violations are displayed.

"5" key
Calls up the fault list.
The current faults and alarms are displayed.
"6" key
Calls up the selected automatic service.
The selected service and the remaining time in seconds until the next
service are displayed.
"7" key
On devices with two sample flows, you can use the "7" key to toggle
between the values displayed on the screen for the two sample flows.
"." key (period key)
The period key indicates the current procedural step in measuring mode.
If you press the period key again, the following data are displayed:
• Temperature
• pH value
• Pressure in gas circuit
• Feed rate of pump P3
"CLR" key
You can display the following information on the screen with the "CLR
key":
• Device type
• Software program version
• Device options

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Operation TOCII CA72TOC

5.3 Operation during measuring mode

The analyzer has three operating modes:
• Measuring mode
• Service mode
• Programming mode
The measuring mode is fully automated. Manual intervention on the part of the user is not
possible.

1000 11:39:04
1

500

2
5 00 6 00 7 00 8 00 9 00 10 00 11 00
3

IR = 334 ppm
234 TOC
mg/l

5 4
a0012443

Fig. 12: Display during measuring operation

1 Time
2 Load curve of the past 6 hours
3 Timeframe
4 Measured value
5 Measured value of the IR detector

5.3.1 Recording mode

Pressing the U key in the measuring mode takes you to the recording mode. Using the arrow
keys, scroll between the measured values recorded:
• V 1 day earlier
• W 1 day later
• U 2 hours earlier
• T 2 hours later
Once you have selected the required period, press the Enter key.
Recording time:
• 14 days for one-channel operation
• 7 days for two-channel operation
Use the operation key to quit recording mode.

32 Endress+Hauser
TOCII CA72TOC Operation

5.3.2 Spot view

The spot view is activated in the recording mode by pressing the Enter key.
The following information is displayed:
• Load curve
• Measured value
• Date
• Time
A small cursor on the display indicates where you are currently in the load curve.

1000
1

500

5 00 6 00 7 00 8 00 9 00 10 00 11 00 2

RECORD VALUE= 238 mg/l

DATE 08/29/08 TIME= 8:30
a0012449-de

Fig. 13: Spot view (example)

1 Time mark on the load curve
2 Measured value of the selected time

V 1 hour earlier U 2 minutes earlier

W 1 hour later T 2 minutes later

You can switch the spot view (cursor) off with the Enter key.

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Operation TOCII CA72TOC

5.4 Standby mode

The standby mode can be used to operate the analyzer at measuring points where the flow
of sample is interrupted at times.
The option is available in the one-channel version with a PA-2 or PA-3 sample conditioning
system.

3
5

2
1

a0013853

Fig. 14: Standby switch

1 Adapter fitting for the pressure monitor
2 Pressure monitor ¼"
3 Signal connection
4 Protection cap
5 Bypass screen

Mode of operation
If the flow of sample is interrupted, the pressure monitor reports this status to the computer
via switch input DI 04.
This causes the device to respond as follows:
• All the pumps are stopped.
• Pump P2 is drained.
• The strip chamber is rinsed.
• The analyzer is on standby and waits for sample.
The device resumes measuring operation automatically as soon as sample flows again.

34 Endress+Hauser
TOCII CA72TOC Commissioning

6 Commissioning

6.1 Function check

! CAUTION
Avoid damages resulting from incorrect power supply and incorrect or poorly executed
hose connections.
‣ Check that all connections have been established correctly. In particular, verify that all
the hose connections are securely positioned to ensure that no leaks occur.
‣ Verify that the line voltage matches the voltage specified on the nameplate.

6.2 Start

6.2.1 Commissioning sequence

Preparation:
1. Install the pH sensor in the strip chamber and connect the sensor cable to the amplifier.
2. Remove the transportation lock (cable ties) on the furnace unlocking device.
3. Place the combustion pipe insert with the catalyst into the furnace (see "Maintenance"
section) and install the heated salt trap (optional).
4. Mount the hose cassettes (see the "Maintenance" section).
5. Place the stripping reagent in the reagent tray beneath the measuring device, and put
the standards C1 and C2 (see "Preparing the chemicals" section) in the reagent bottle
holders provided on the left side panel.
Starting the analyzer:
1. Switch on the analyzer. The furnace begins to heat up.
2. In the programming mode, configure the operating parameters of the analyzer.
3. Adjust the pH sensor (> CALIBRATION > ADJUSTMENT pH SENSOR).
4. Adjust the peristaltic pumps P1 and P4 (> PUMPS > REPLACE HOSE P1/4).
5. Adjust the peristaltic pump P2 and determine the empty volume ( > PUMPS > ADJUST
P2 and > CALIBRATION > EMPTY VOLUME DOSING).
6. Once the analyzer is in operation following warm-up and the temperature is stable,
check the gas circuit for leaks (> CLEANING > LEAKAGE TEST).
7. Perform a 2-point adjustment ( > CALIBRATION > ANALYZER ADJUSTMENT).

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Commissioning TOCII CA72TOC

6.2.2 Updating the analyzer software

Regardless of the menu structure, you can update the analyzer software via the USB
interface.
! WARNING
Risk of electric shock!
Defective device connected to USB.
‣ Use only passive USB devices.

Step Display Description

1 1. Switch off the main switch.

2. Plug the USB stick with the
desired software into the USB
interface.
3. Switch the main switch back on.
Logo appears.

2 Press the [CLR] key.

3 Press [1] key.

Keys [2] and [3] are reserved for

E+H Service.

[CLR] Cancel and start existing

analyzer software

4 A list of all software versions

available is displayed.
[▴▾] Scroll up and down

[◂▸] Page through (if more than

12 versions are available)

[.] Select software version

(* = marking)

[CLR] Delete software version

(! = marking)

[E] Confirm

Only one version can be

selected for updating. Several
versions can be selected for
deletion.

36 Endress+Hauser
TOCII CA72TOC Commissioning

Step Display Description

5 [E] Confirm the selected software

version and start the software.

[CLR] Back to selection menu

The analyzer goes into

measuring mode once the
software has been started. You
can check the software version
when in measuring mode using
the [CLR] key.

6 Remove the USB stick once the

software has been updated.

The software versions will remain available in memory until they are deleted. For
improved clarity, it can be useful to delete these software versions if further updates are
carried out.

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Commissioning TOCII CA72TOC

6.3 Programming mode

You configure the operating parameters of the analyzer in the programming mode.
1. Press the programming key.
2. Enter the "code". The code is a four-digit number which you can find on the code card
supplied with your analyzer.
3. Press the [E] key.
The following menu appears:

a0012583-en

Fig. 15: "Programming" menu

The operating parameters are stored in the analyzer and are retained in the event of a
software update.
Within the menu items, pressing the [<] key takes you back to the "Programming" menu.

6.3.1 Menu SETTING - RANGE DATA

a0012553-en

Fig. 16: Menu "Setting"

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Parameter Unit Factory Description

setting

SCALE mg TOC/l 1000 Use this function to enter the maximum concentration
for your measuring point here. This value determines
the scale end value for the graphic interface.
Enter two independent values for the two-channel
version.

SCREEN FLUSH n/day 0 The number of automatic flush cycles for the bypass
screen per day (recommended value: 2).

DURA.SCREEN s 15 When a screen flush is activated, the duration of the

FLUSH flush can be altered. If longer than 15 seconds, two
thirds of the flush time is assigned to flushing the
screen and one third to flushing the strip chamber.

POWER FLUSH n/day 0 The number of automatic power flush cycles for the
stripping vessel and separation chamber per day
(recommended value: 2).

PAUSE CYCLE s 0 Interval between 2 measurements.

P1 (B) ml/min 7.5 Feed rate of pump P1.

P2 (B) μl/min 250 Feed rate of pump P2.

P4 (B) ml/min 5.0 Feed rate of pump P4 (optional). The feed rates of
pumps P4 and P5 determine the dilution ratio.

P5 (B) ml/min 25.0 Feed rate of pump P5 (optional). The feed rates of
pumps P4 and P5 determine the dilution ratio.

VOL.BATCH μl 300 Dosing volume for a batch. Increasing the volume

increases the sensitivity of the measuring system but
also increases the salt load.

STANDARD C1 mg/l 80 Concentration of standard solution C1.

STANDARD C2 mg/l 720 Concentration of standard solution C2.

CAL./ADJUST. n days 3 Here you can specify after how many days a calibration
or adjustment should be performed. The automatic
function is switched off with the value 0.

CAL./ADJUST. TIME xx.xx 23.00 Here you can specify the start time for the calibration or
adjustment. Enter as a decimal number. Example:
22.50 corresponds to 22:30 hrs.

CAL/ADJUSTMENT 2 Use this function to specify which function should be

executed.
• 1 - Calibration
• 2 - Adjustment
The function is executed 90 minutes before the day
changes.

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6.3.2 Menu SETTING - BASIC DATA

a0012580-en

Fig. 17: "Programming" menu

Parameter Unit Factory Description

setting

DC OUT mA 0 Sets the signal output to 0 to 20 mA or

4 to 20 mA.

DC OUT STANDBY mA 0 Sets the signal output as follows:

• 0: signal output is set to 0mA
• 1: signal output is set to 3.6 mA
• 2: signal output in mA is held (last measured value)
• 3: signal output is set to 21 mA

DC OUT mA 0 Sets the signal output as follows:

CALIBRATION
• 0: in the event of a calibration, the last measured
value is transmitted to the analog output. This output
is set to "Hold" until the calibration value has been
determined. The calibration value is then transmitted
to the analog output until a new measured value has
been determined for the current sample.
• 1: signal output in mA is held (last measured value)
until a new measured value has been determined

SCALE AO mg/l 1000 Scale end value of the analog output.

e.g. 1000 mg/l = 20 mA

EMPTY VOLUME P2 μl 220 Dead volume of pump P2 from the separation chamber
* to the end of the capillary.

P1 100% * ml/min 5.6 Feed rate of pump P1 at 100 % pump capacity.

P2 100% * μl/min 870 Feed rate of pump P2 at 100 % pump capacity.

P3 100% μl/min 870 Feed rate of pump P3 at 100 % pump capacity.

P4 100% * ml/min 5.6 Feed rate of pump P4 at 100 % pump capacity

(optional).

P5 100% * ml/min 30 Feed rate of pump P5 at 100 % pump capacity

(optional).

ADJUSTMENT Do not change this value!

CONSTANTS

X0 * 0.0 Offset, value is overwritten during adjustment

KP * 50 Slope, value is overwritten during adjustment

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Parameter Unit Factory Description

setting

PH-CONTROL 1.00 The measuring device is equipped with automatic pH

control in the stripping vessel. You can use this
parameter to switch pH control on or off.
• 1.00 = pH control is switched on
Reading on display = TOC
• 0.00 = pH control is switched off
Reading on display = TC

PH-NOMINAL 2.5 The pH value in the stripping vessel is set here. The pH
value must be between 1 and 4 for complete stripping.
If the sample becomes excessively acidic in municipal
sewage treatment plants, there is the problem of humic
acid precipitating which could mask the carbonate. This
inorganic carbon enters the furnace and results in
excessively high readings.

PH ADJ.OFFSET * 2.4 Offset of the pH sensor. The value is overwritten when

the pH sensor is adjusted.

PH ADJ. SLOPE * mV/ 57.5 Slope of the pH sensor. The value is overwritten when
decade the pH sensor is adjusted.

* These parameters are adapted by means of menu-guided adjustments.

6.3.3 Menu SETTING - ALARM LIMITS

Use this function to enter the limit values for the high alarm and low alarm.

a0012579-en

Fig. 18: "Programming" menu

Parameter Unit Factory Description

setting

HIGH ALARM LIMIT mg/l 12000 Use this function to specify the alarm value for when
the value is overshot.

LOW ALARM LIMIT mg/l 0 Use this function to specify the alarm value for when
the value is undershot.

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6.3.4 Menu SETTING - SET CLOCK

This section describes how you enter the date and the time.
Select the programming mode for this purpose.

Step Display Description

2 [] increases value by 1.

[] reduces value by 1.
[] to go to previous value
[] to go to next value
[E] confirms the displayed value.

6.3.5 Menu SETTING - SET BRIGHTN./CONTR.

Step Display Description

2 [E] confirms the displayed value.

[] and [] switch between
brightness and contrast.
[] increases value by 1.
[] reduces value by 1.
Range: 0 to 100 %

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6.3.6 Menu SETTING - MEASURING SITE

You can give the measuring point a name.

a0012582-en

Fig. 19: "Programming" menu

In the factory setting, the name is MEASURING SITE.

• Select the position of the character using the cursor buttons T and U.
• Select the character using the V and W cursor buttons.
• Pressing the "1" key switches the character to "A".

6.3.7 Menu LISTS - SHOW COMPLETE RECORDS

a0012588-en

Fig. 20: "Lists" menu

Chronological display of all the events saved. The last 200 events are saved in the complete
record list.

XX.XX XX:XX XXXXXXXXXXXXX

XX.XX XX:XX XXXXXXXXXXXXX

Date Time Event

a0012593-en

Fig. 21: Complete records

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6.3.8 Menu LISTS - ALARM RECORD

a0012587-en

Fig. 22: "Lists" menu

All the alarm messages, including the date and time of the event, are logged in the alarm
record.

ALARM RECORD

Date Time Event on/off

XX.XX XX:XX XXXXXXXXXXXXX XXX

XX.XX XX:XX XXXXXXXXXXXXX XXX
a0012592-en

Fig. 23: Alarm record

Alarm Description

ALARM T<Tmin Furnace temperature drops below 85 % of the set value

Operation stops.
System starts as soon as 90 % of the set value is reached.

TEMPERATURE TOO HIGH Furnace temperature exceeds the set value by more than 70 °C (126 °F)
The furnace and stripping gas supply are switched off.
The analyzer must be started manually.

TEMPERATURE TOO LOW Furnace temperature drops below the set value by 30 °C (54 °F).

ACID FAILURE Acid failure

CARRIER FAILURE Failure of carrier gas

The supply pressure has dropped below 1.5 bar (21 psi).
The analyzer must be started manually.

MALFUNCTION PELTIER Peltier cooler malfunction

Operation stops. The analyzer restarts automatically once the error
status is reset.

VALUE>MEASURING RANGE The value is outside the measuring range

The IR detector has been working above its maximum value for over
10 minutes or the measuring device has been measuring 0 mg/l for
over an hour.

MALFUNCTION IR IR detector is defective

Operation stops. The analyzer restarts automatically once the error
status is reset.

LEAKAGE Leak in the system

The furnace and carrier gas supply are switched off.
The analyzer must be started manually.

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Alarm Description

ADJUSTMENT ERROR Adjustment error

An error number is assigned to the error.

UNSTABLE DOSING Error when dosing the sample

The minimum number of drops to be expected was undershot.

WATER PRESS. FAILURE Failure in the supply of water for flushing and dilution
The minimum permitted pressure of approx. 1.5 bar (21 psi) was
undershot.
Operation stops. The analyzer restarts automatically once the error
status is reset.

CO2 BASIC LINIE The limit value for the CO2 drift (ppm/min) or for the CO2-threshold
value (ppm) was overshot in basic line measurement.

Value 1: Basic line drift slope [ppm/min]

Value 2: Basic line offset [ppm]

INPUT ERROR C1>C2 Error during entry of standard concentrations. The concentration of
standard C1 must be lower than the concentration of standard C2.

CIRCUIT PRESSURE HIGH At 175 mbar, the pressure in the gas circuit is 70 % above the pressure
permitted in the gas circuit (250 mbar).

CIRCUIT PRES.TOO HIGH The maximum permitted pressure in the gas circuit has been exceeded.
The max. set value for pressure is 250 mbar.

INTERNAL COM-FAULT Fault in internal communication between I/O card, keyboard and
modbus connection. Operation stops.
The analyzer restarts automatically once the error status is reset.

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6.3.9 Menu LISTS - MAINTENANCE RECORD

a0012586-en

Fig. 24: "Lists" menu

All the maintenance procedures are recorded by maintenance activity in the maintenance
record. Maintenance procedures that have not been carried out cannot be selected.

Action Description

PROGRAM STARTED Date and time when program starts

CHANGE DATA Date and time of when the setting data are changed

CHANGE TIME Date and time when clock changes

The newly set time and the time difference in hours compared to the
old time are documented.
Negative value: The clock was put back.
Positive value: The clock was put forward.

ADJUSTMENT Date and time of when the analyzer and the CO2 concentrations of the
standard solutions are adjusted
Value 1: CO2 concentration of C1 [ppm]
Value 2: CO2 concentration of C2 [ppm]

ADJUSTMENT CONSTANTS Date and time and the adjustment constants obtained during
adjustment
Value 1: Offset [ppm]
Value 2: Standardized slope [ppm]

CALIBRATION Date and time of the calibration of the analyzer and the TOC value
found, and the recovery with regard to the specified concentration of
standard C2
Value 1: TOC [mg/l]
Value 2: Recovery [%]

BASIC LINE DRIFT Date and time of the basic line drift when calibrating and adjusting
Value 1: Basic line offset [ppm]
Value 2: Basic line drift slope [ppm/min]

EMPTY VOLUME DOSING Date and time when selected in the service menu
Value 1: Duration of the filling process [s]
Value 2: Volume [μl]

ADJUSTMENT PUMP P1 Date and time of when pump P1 is adjusted

Value 1: new feed rate (ml/min)
Value 2: old feed rate (ml/min)

ADJUSTMENT PUMP P2 Date and time of when pump P2 is adjusted

Value 1: new feed rate (μl/min)
Value 2: old feed rate (μl/min)

ADJUSTMENT PUMP P4 Date and time of when pump P4 is adjusted

Value 1: new feed rate (ml/min)
Value 2: old feed rate (ml/min)

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Action Description

ADJUSTMENT PH-SENSOR Date and time and the adjustment constants obtained during
adjustment
Value 1: Offset [mV]
Value 2: Slope [mV/log pH]

REPLACE HOSE P1 Date and time of when the hose of pump P1 is changed

REPLACE HOSE P2 Date and time of when the hose of pump P2 is changed

REPLACE HOSE P3 Date and time of when the hose of pump P3 is changed

REPLACE HOSE P4 Date and time when the hose of pump P4 is changed when sample
pre-dilution is present

SCREEN FLUSH Date and time when selected in the service menu
Automatic screen flushing is not logged.

BYPASS SCREEN Date and time when selected in the service menu

POWER FLUSH Date and time when selected in the service menu
Automatic power flushing is not logged.

STRIPPING+SEPARATION Date and time when selected in the service menu

OPEN GAS CIRCUIT Date and time when selected in the service menu

COMBUSTION PIPE Date and time when selected in the service menu

LEAKAGE TEST Date and time when exiting the leak tightness display
Value 1: Current pressure
Value 2: Current leakage rate [mbar/min]
Typical value: -0.5 to -2.0 mbar/min

REPLACE ACID FILTER Date and time when selected in the service menu

REPLACE GAS FILTERS Date and time when selected in the service menu

HEATED FILTER Date and time when selected in the service menu
(heated salt trap)

REPLACE O2 FILTER Date and time when selected in the service menu

STANDBY Date and time of a standby event

SAVE DEFAULTS Date and time when selected in the Setting menu

SET DEFAULTS Date and time when selected in the Setting menu

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6.3.10 Menu LISTS - MIN MAX AVERAGE

a0012585-en

Fig. 25: "Lists" menu

This menu item displays the maximum, minimum and average measured values for the days
saved.

6.3.11 Menu LISTS - RECORD ALL DATA

This menu item is used to save the measuring data and protocols from the last 14 days. The
data records are available as csv files.

Step Display Description

2 RECORD DATA If the time or the date are changed

within these 14 days, the data will be
01 - 06.02.2013 08 - 30.01.2013
02 - 05.02.2013 09 - 29.01.2013 re-dated accordingly.
03 - 04.02.2013 10 - 28.01.2013 If the date change is outside of these
04 - 03.02.2013 11 - 27.01.2013
05 - 02.02.2013 12 - 26.01.2013 14 days, the memory will be
06 - 01.02.2013 13 - 25.01.2013 completely deleted.
07 - 31.01.2013

[E] TO END [1] SAVE

3 Connect the storage medium to the

USB connection.

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Step Display Description

4 RECORD DATA
01 - 06.02.2013 08 - 30.01.2013
02 - 05.02.2013 09 - 29.01.2013
03 - 04.02.2013 10 - 28.01.2013
04 - 03.02.2013 11 - 27.01.2013
05 - 02.02.2013 12 - 26.01.2013
06 - 01.02.2013 13 - 25.01.2013
07 - 31.01.2013

SAVE DATA, PLEASE WAIT 01:55

5 USB CAN NOW BE REMOVED Always remove the storage medium!

[E] TO END

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6.3.12 Menu TEST - INPUT TEST

Step Display Description

1
1. Select the desired inputs.
2. Press the [E] key.

2 Analog inputs
Current CO2 measured value
• T1 = Temperature furnace
monitoring
• T2 = Temperature heating
regulation furnace, PWM
performance display
• T3 = Temperature heating
regulation salt trap, PWM
performance display
• pH value in stripping vessel
• Pressure level in gas circuit

Switch inputs

Switching status of the switch inputs

Ix = 0 = OFF
Ix > 0 = ON

IN1= Peltier cooler, Peltier regulator

BI34
IN2= Peltier cooler, Peltier regulator
IN3= Dilution water BI35
IN4= Standby no. BI30
IN5= Leak detector no. BI29
IN6= Carrier gas pressure switch BI28

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6.3.13 Menu TEST - OUTPUT TEST

Step Display Description

1 1. Select the desired outputs.

2. Press the [E] key.

2 MEASUREMENT OFF deactivates measuring mode. The MEASUREMENT OFF operating status is
displayed. Select this status to test the inputs without triggering an alarm.

3 TEST DC-SIGNAL Current output

Sets the analog current outputs to any
CHANNEL NO. 1 0.0 mA value between 0 and 20 mA.
CHANNEL NO. 2 0.0 mA

4 Pumps
Parameter for testing the function of
the pumps
Negative value turns the direction of
flow.

5 SWITCH OUTPUTS Switch outputs

Displays the switching status of the
SA NO. OFF SA NO. OFF
switch outputs (see the following
SA NO. OFF SA NO. OFF
SA NO. ON SA NO. OFF table).
SA NO. OFF SA NO. OFF ON/OFF using Enter key
SA NO. OFF SA NO. OFF
SA NO. OFF SA NO. OFF
SA NO. OFF SA NO. OFF
SA NO. OFF SA NO. OFF

TO QUIT

6 TEST COM TEST COM displays the transmission

data for the computer interface
RS 232.
The menu item allows users to test
the transmission of data with an
... external terminal.
Once the data connection is
established, a data string is
[E] TO END transmitted every 2 seconds.
Keystrokes at the external terminal
are shown on the display. Entries at
the terminal must be transmitted
using a carriage return.

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Output Description Switch status OFF Switch status ON

(contacts opened) (contacts closed)

SA1 Changeover between standard and Sample Standard solution

sample

SA2 Flushing valve for power flushing Strip chamber flushing Strip chamber flushing
switched off switched on

SA3 Stripping gas supply, tube furnace Consumer load switched off Switch status during
regulator, Peltier cooler regulator, measuring operation
membrane compressor

SA4 Changeover between standard 1 and Standard 1 Standard 2

standard 2

SA5 Screen flushing valve Screen flushing valve off Screen flushing valve on

SA6 Optional: Changeover between channel Channel 1 Channel 2

1 and channel 2
SA7 Carrier gas flushing valve Carrier gas flushing off Carrier gas flushing on

SA8 Dosing valve Dosing valve open Dosing valve closed

SA9 Collective alarm fault relay I Fault on Fault off

(e.g. failure acid, leak)

SA10 Collective alarm limit values relay II Limit value alarm on Limit value alarm off

SA11 Standby relay III Standby off Standby on

SA12 Operation check relay IV At the end of the measuring During operation, the
cycle in measuring mode, contact is closed as soon as
the contact is opened for 2 the displayed measured
sec to signal the end of the value is reliable (e.g.
measuring cycle. If the following a service, this
analyzer is in service mode contact is closed once the
or in a fault state in which first TOC measured value
TOC measurement is not has been determined).
permitted, the contact is
opened.

6.3.14 Two-channel: external changeover

The analyzer is equipped with one or two separate sample supply systems.
The current sample selected is controlled externally by signal input 8 (binary in 8).
Signal input 8 = 0 channel 1
Signal input 8 = 1 channel 2
If the analyzer is operated with one sample conditioning system, the operator must ensure
that the right sample is at the bypass when a channel switch is requested.
If the analyzer is operated with two sample conditioning systems, the solenoid valve MV6 is
used internally to switch the channels.
If the signal status at signal input 8 changes, the measuring cycle is terminated immediately
and the system immediately commences channel switchover.
If the "Operation" key is pressed during channel switchover, the process of switching
channels is aborted and the measuring cycle commences in the active channel. Conditioning
of the analyzer to the sample in the active channel is suppressed.
The measuring channel cannot be switched manually.

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Settings for the graphic interface

You must enter the following parameters in the Range Data menu:

PROGRAMMING/SETTING/RANGE DATA:

Parameter Unit Description

SCALE CH1 mg TOC/l Use this function to enter the maximum concentration for
channel 1 here. This value determines the scale end value for
the graphic interface.

SCALE CH2 mg TOC/l Use this function to enter the maximum concentration for
channel 2 here. This value determines the scale end value for
the graphic interface.

Settings for the analog outputs

You must enter the following parameters in the Basic Data menu:

PROGRAMMING/SETTING/BASIC DATA:

Parameter Unit Description

SCALE AO CH1 Scale end value of the analog output of channel 1.

SCALE AO CH2 Scale end value of the analog output of channel 2.

Settings for the alarm limits

You must enter the following parameters in the ALARM LIMITS menu:

PROGRAMMING/SETTING/ALARM LIMITS:

Parameter Unit Description

HI ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value
for channel 1 is overshot.

LO ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value
for channel 1 is undershot.

HI ALARM LIMIT CH2 mg/l Use this function to specify the alarm value for when the value
for channel 2 is overshot.

LO ALARM LIMIT CH2 mg/l Use this function to specify the alarm value for when the value
for channel 2 is undershot.

All the alarm limits affect the same signal output II (binary out II). A limit value alarm is also
retained following channel switchover until the limit value for the channel in question is
undershot.

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6.3.15 Two-channel: time-controlled changeover

The analyzer is equipped with two separate sample supply systems.

Configuring the measuring duration

The measuring duration can be individually configured for each channel.

PROGRAMMING/SETTING/BASIC DATA:

Parameter Unit Description

DURATION CH1 min Measuring duration for channel 1

DURATION CH2 min Measuring duration for channel 2

If you configure a duration of 0 minutes in one channel, measurement will be performed

permanently in the other channel. You have to set a duration greater than 0 minutes for at
least one channel.
Regardless of the measuring duration configured, any measuring cycle that has started
will always be completed before the system switches to the other channel.
In the case of an external switchover, the other channel is switched over to immediately.

Settings for the graphic interface

Using key 7 you can switch over to the graphic screen for the channel which was not
selected.

You must enter the following parameters in the Range Data menu:

PROGRAMMING/SETTING/RANGE DATA:

Parameter Unit Description

SCALE CH1 mg TOC/l Use this function to enter the maximum concentration for
channel 1 here. This value determines the scale end value for
the graphic interface.

SCALE CH2 mg TOC/l Use this function to enter the maximum concentration for
channel 2 here. This value determines the scale end value for
the graphic interface.

Settings for the analog outputs

You must enter the following parameters in the Basic Data menu:

PROGRAMMING/SETTING/BASIC DATA:

Parameter Unit Description

SCALE AO CH1 Scale end value of the analog output of channel 1.

SCALE AO CH2 Scale end value of the analog output of channel 2.

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Settings for the alarm limits

You can enter the following parameters in the ALARM LIMITS menu:

PROGRAMMING/SETTING/ALARM LIMITS:

Parameter Unit Description

HI ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value
for channel 1 is overshot.

LO ALARM LIMIT CH1 mg/l Use this function to specify the alarm value for when the value
for channel 1 is undershot.

HI ALARM LIMIT CH2 mg/l Use this function to specify the alarm value for when the value
for channel 2 is overshot.

LO ALARM LIMIT CH2 mg/l Use this function to specify the alarm value for when the value
for channel 2 is undershot.

All the alarm limits affect the same signal output II (binary out II). A limit value alarm is also
retained following channel switchover until the limit value for the channel in question is
undershot.

Interrupting the time control system

Regardless of the internal time-based control system, the channel can be changed manually,
or by remote control via the external signal input 8 (binary in 8).
Using keys 1 and 2 users can manually change to the other channel during measuring
operation.
Channel changeover can be triggered remotely using signal input 8.
Signal input 8 = 0 has no effect
Signal input 8 = 1 (for approx. 10 seconds) switch to other channel
If you trigger channel changeover by using the keyboard or the signal input, the measuring
cycle is terminated immediately and the channel changeover initiated.

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6.4 Optimizing the analyzer

6.4.1 Adjusting the measuring range

Depending on its configuration, the analyzer can measure from just a few mg/l to several
10 000 mg/l. The analyzer can be optimized by changing components and altering the
device settings.
The measuring range is altered by changing a component:
• By changing the infrared detector (Endress+Hauser Service)
• By fitting a predilution system (Endress+Hauser Service)
In terms of device settings, the feed rate of dosing pump P2 is optimized.
Please note that optimizing the sensitivity or the salt load compatibility often demands
conflicting settings on the analyzer. Select the settings the offer the best compromise for
your measuring task.

6.4.2 Influence of dosing volume (pump P2) on the measuring signal

The dosing range of adjustment is affected by:
• Dosing volume BATCH VOL. (100 to 1200 μl)
You can change the pump setting in the programming mode: SETTING - RANGE DATA.
An increase in the dosing volume (P2) increases the measuring signal, with a 50 % increase
in the feed rate being equivalent to an approx. 50 % increase in the signal.
The dosing volume of 400 μl/batch results in a sensitivity of 2 ppm CO2 per mg/l TOC
(dosing volume 100 to 1200 μl/batch is equivalent to 0.5 to 6 ppm CO2 per mg/l TOC).
Please note that if the sample flow is increased, the salt load also increases to the same
extent.
The maximum measuring range indicated on the nameplate is the range at a dosing volume
of 100 μl/batch and 1200 μl/batch.

Measuring range Dosing Set measuring range

0.25 to 600 mg TOC/l 100 μl/batch 3 to 600 mg/l

300 μl/batch 1 to 200 mg/l
1200 μl/batch 0.25 to 50 mg/l

1 to 2400 mg TOC/l 100 μl/batch 12 to 2400 mg/l

300 μl/batch 4 to 800 mg/l
1200 μl/batch 1 to 200 mg/l

2.5 to 6000 mg TOC/l 100 μl/batch 20 to 6000 mg/l

300 μl/batch 8 to 2400 mg/l
1200 μl/batch 2.5 to 500 mg/l

5 to 12000 mg TOC/l 100 μl/batch 60 to 12000 mg/l

300 μl/batch 24 to 4800 mg/l
1200 μl/batch 5 to 1000 mg/l

Factory setting:
Version A and B: 300 μl/batch
Version C and D: 250 μl/batch

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6.4.3 Operating the analyzer with high salt loads

Completely diverse salt loads can occur given the different range of applications of the
analyzer. For the user, this can mean that the salt load reduction function has to be
optimized. The dosing pump P2 can be used to reduce the dosing volume and therefore the
salt load. To reduce the salt load, it is also possible to program a break in measurement.
For very high salt loads, an optional dilution module is available.
Dilution ratios between 1:5 to 1:20 are possible. The effective TOC concentration in the
diluted wastewater should be inside the measuring range of the analyzer.

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6.5 Communication
The analyzer is equipped with an RS-232 serial interface.
Data transmission is unidirectional and is performed with the following parameters:

Baud rate 9600 baud

Bits 8 bit
Parity N
Stop bit 1 bit
Handshake No
The string is 104 bytes long and is sent every 2 seconds.

Byte Description

0 Start byte

1 0 = Operation disabled
1 = Operation enabled

2 0 = Emergency shutdown
1 = Channel 1 measuring operation enabled
2 = Adjustment or calibration
3 = Service
4 = Programming
5 = Channel 2 measuring operation enabled

3 Leakage (0 = off, 1 = on)

4 Temperature too high (0 = off, 1 = on)

5 Low carrier gas supply (0 = off, 1 = on)

6 IR detector fault (0 = off, 1 = on)

7 Temperature too low (< 85 % Tset) (0 = off, 1 = on)

8 Outside the measuring range (0 = off, 1 = on)

9 Temperature deviation of Peltier cooler (Tset ± 3 °C) (0 = off, 1 = on)

10 pH alarm (0 = off, 1 = on)

11 Temperature deviation (< Tset -30 °C) (0 = off, 1 = on)

12 Standby (0 = off, 1 = on)

13 Limit value exceeded (0 = off, 1 = on)

14 Limit value undershot (0 = off, 1 = on)

15 Slope alarm (0 = off, 1 = on)

16 Unstable dosing, sample failure (furnace) (0 = off, 1 = on)

17 Water supply failure (0 = off, 1 = on)

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Byte Description

18 Gas circuit pressure monitoring

0 = OK
1 = 70 % of max. permitted pressure
2 = > max. permitted pressure

19 Check CO2 basic line (0 = off, 1 = on)

20 Adjustment error (0 = off, 1 = on)

21 Empty (unused byte)

22 Empty (unused byte)

23 0 = No valid measured value available

1 = Valid measured value available
2 = New measured value determined (displayed for approx. 4 seconds)

24 Separator

25 0 = Sample
1 = Standard is dosed

26 Flushing strip and separation chamber with supply water

27 0 = Error shutdown active, no power is supplied to any of the units

powered by the power relay
1 = Power supply active

28 0 = Standard C1 is dosed
1 = Standard C2 is dosed
If relay 1 (byte 25) is set to 1

29 Flushing sample conditioning

30 Only important for two-channel operation

0 = Sample is taken from sample channel 1
1 = Sample is taken from sample channel 2

31 Flushing with carrier gas

32 A 0-1-0 change indicates that the process of dosing the sample into the
furnace has been completed.

33 Separator

34 ... 39 TOC measured value (mg/l)

1 decimal place for measuring range A and B
0 decimal places for measuring range C and D

40 Separator

41 ... 46 Only for channel 2

TOC measured value (mg/l)
1 decimal place for measuring range A and B
0 decimal places for measuring range C and D

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Commissioning TOCII CA72TOC

Byte Description

47 Separator

48 ... 53 CO2 (ppm)

1 decimal place; current value of the gas card

54 Separator

55 ... 60 CO2 (ppm)

1 decimal place; CO2 difference calculated from the measuring cycle

61 Separator

62 ... 67 pH value
2 decimal places

68 Separator

69 ... 74 Number of drops dosed into furnace

No decimal places

75 Separator

76 ... 81 Batch status

82 Separator

83 ... 92 Date DD.MM.YYYY

93 Separator

94 ... 101 Time HH:MM:SS

102 Carriage return

103 Line feed

104 End of transmission

60 Endress+Hauser
TOCII CA72TOC Diagnostics and troubleshooting

7 Diagnostics and troubleshooting

The analyzer permanently monitors its functions automatically. Any errors detected by the
analyzer are shown on the display. If several errors are detected, these errors are displayed
in a list by pressing key 5.
! WARNING
The device is energized.
Troubleshooting that is not performed correctly may result in injury or death.
‣ Troubleshooting work on the components behind the mounting plate may only be carried
out by an electrical technician.
! CAUTION
There is a risk of infection when working with wastewater, and there is a risk of injury
when working with reagents.
‣ Wear acid-resistant protective gloves, protective goggles and a laboratory coat!

7.1 Error messages

Message Cause Tests or remedial action

Temperature The temperature at • Select INPUT TEST. The temperatures are displayed. If there
too high the tube furnace is is a significant variation in the temperatures, check the
70 °C above the set temperature sensor.
point. • It is possible that the furnace will be permanently heated.
Remove the PWM connection (cable 54). If the temperature
Possible defect: continues to rise, check relay RB.
Temperature sensor, • Select INPUT TEST. If the PWM control system continuously
relay RB, PWM1, outputs 200 %, there is a malfunction in the PWM. Switch
I/O card the main switch off and on - if the error persists, replace the
I/O card.

Temperature The temperature is • Select INPUT TEST. The temperatures are displayed. If the
too low 15 % below the set temperature increases in INPUT TEST, wait until the warm-
point. up stage has stabilized. If there is a significant variation in the
When putting back temperatures, check the temperature sensor. Verify that the
into operation, or temperature sensors are secured and positioned correctly on
during service or the furnace pipe. Are the contacts on the furnace connection
maintenance socket and the I/O card correctly connected.
• It is possible that the furnace will not be heated. Check the
Possible defect: relay RB.
Cable, temperature • Select INPUT TEST. If the PWM control system does not
sensor, relay RB, regulate and continuously outputs 200 % or 0 %, there is a
PWM1, I/O card malfunction in the PWM. Switch the main switch off and on -
if the error persists, replace the I/O card.
Temperature The measured
below xxx °C temperature is
30 °C below the set
temperature.
When putting back
into operation, or
during service or
maintenance

Possible defect:
Temperature sensor,
relay RB, PWM1,
I/O card

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Diagnostics and troubleshooting TOCII CA72TOC

Message Cause Tests or remedial action

Carrier gas The pressure sensor • Monitor the carrier gas supply.
failure for monitoring the • Check signal processing (I/O card slot no. 28 switch input
carrier gas has been DI06)
triggered. Go to the programming module PRG/TEST/INPUTS/SWITCH
Pressure < 1.5 bar. INPUTS. Release the connecting cable on the pressure switch
Failure of carrier gas and short-circuit the contacts. The switch state of DI06
supply should react on the display.
If it does, replace the pressure switch.
Possible defect: If it does not, use a multimeter to check that there are no
Pressure sensor, interruptions in the cable. If the cable is OK, replace the I/O
cable or I/O card card.

Leakage The leak detector • Check for leaks.

has been triggered. • Check the leak alarm for an electrical short-circuit of the
Leaks in the spring contacts.
measuring device if • Check signal processing (I/O card slot no. 29 switch input
the springs of the DI05)
leak detector have Go to the programming module PRG/TEST/INPUTS/SWITCH
been bridged. INPUTS. Plug the cable for the carrier gas pressure switch into
slot 29. The display should change at switch input DI05 when
Possible defect: the connecting contacts on the pressure switch are bridged
Leak detector, cable, manually.
I/O card If so, replace the leak detector.
If not, replace the I/O card.

Malfunction The Peltier cooler Green LED on → Peltier cooler at operating temperature.
Peltier deviates > 3 °C from Red > °C LED on → Peltier cooler is too warm.
the set point. Red < °C LED on → Peltier cooler is too cold, control system is
Following servicing defective.
or maintenance, in
• If no LED is lit, check the power supply of the Peltier cooler
the event of high
control system.
ambient • If the green LED is on, check the transmission cable to the I/O
temperatures, in the
card and the I/O card itself. If the cable is OK, replace the I/O
event of unfavorable
card.
suction conditions of • If the red LED > °C is on, check the function of the ventilator
the ventilator
on the cooler. Can the ventilator not draw in a sufficient
amount of air? Is the air temperature too high?
Possible defect: • Is the red LED < °C on?
Ventilator failure,
Peltier cooler is too cold, control system is defective, replace
cable defective,
the Peltier cooler control system.
power supply outage

IR detector The measuring The IR detector switches to an automatic warm-up phase

malfunction signal of the IR following a power outage. The IR detector does not supply any
detector has failed. power during this time. The phase is finished after approx. 30 s
f < 10000 Hz and the analyzer switches automatically to the measuring
After a brief power mode.
outage. • In the event of an error (malfunction constantly present after
60 s).
Possible defect:
• Check the connecting cable between the I/O card and the IR
Cable, I/O card, detector.
IR detector
• Replace the cable of the gas card with another cable (e.g. pH
amplifier to the I/O card and check the signal input. Go to the
programming module PRG/TEST/INPUTS/ANALOG INPUTS
(I/O card slot no. 24 FI2 frequency input).
• Replace the IR detector if the I/O card is OK.

62 Endress+Hauser
TOCII CA72TOC Diagnostics and troubleshooting

Message Cause Tests or remedial action

Acid failure If the pH value • Check the acid cistern

permanently • Is the acid concentration sufficient? Does the acid pump
deviates more than operate at a maximum feed rate of 200 %?
±2.5 from the set Increase the acid concentration in the feeder.
point. • Is acid being dosed?
Severely fluctuating In the program module PRG/TEST/OUTPUTS/PUMPS, test
buffer capacity pump P3 by specifying values manually.
values Check the pump hose for leaks.
• Adjust the pH sensor.
Possible defect: • Check signal processing (I/O card slot no. 26 frequency input
Cable interruption, FI4): Disconnect the modular jack on the I/O card slot no. 26 -
pump hose, leaks, does the measured value drop?
pump control, pH Replace the I/O card if there is no change in the display value.
measurement

Unstable dosing The drop monitor • Is sample in the separation chamber?

does not count any, • Is pump P2 pumping medium?
or too few drop Can dripping be observed at the dosing head?
events • Is the pressure sensor OK?
Go to the programming module PRG/TEST/INPUTS/ANALOG
INPUTS and observe the pressure sequence when medium
drips. Can a pressure increase > 10 mbar be observed?
Is the furnace fitted with the combustion pipe insert?
• Check signal processing: Remove the connector at MI4
(cable 53) and plug it back in. If the display has frozen, there
is a malfunction in the I/O card. Switch off the main switch,
wait a few seconds and switch it back on. If the error persists,
replace the I/O card.

Failure of water The pressure sensor • Check the water supply.

pressure for monitoring the • Check signal processing (I/O card slot no. 35 switch input
water supply has DI03):
been triggered. Go to the programming module PRG/TEST/INPUTS/SWITCH
Water pressure < 1 INPUTS. Release the connecting cable on the pressure switch
bar and short-circuit the contacts. The switch state of DI03
should react on the display.
Possible defect: If it does, replace the pressure switch. If it does not, use a
Pressure monitor, multimeter to check that there are no interruptions in the
cable, I/O card cable.
If the cable is OK, replace the I/O card.

Gas circuit The pressure sensor • Check the gas circuit for blockages. In particular, check the
pressure high measures a high acid filter, water trap, reactor and, if necessary, the heated
pressure in the gas salt trap. Has the gas circuit flow rate fallen below 0.7 l/min?
circuit. Eliminate the blockage.
A blockage is • Is the pressure sensor OK?
forming in the gas Go to the programming module PRG/TEST/INPUTS/ANALOG
circuit. INPUTS and observe the pressure sequence. Increase the
pressure by manually squeezing the gas circuit hose for
Possible defect: dosing. Can a pressure increase be observed?
Pressure sensor, • Check signal processing:
cable, I/O card Is the plug correctly inserted in the multi in (MI) on the I/O
card?
Gas circuit The pressure sensor Remove connection MI4 (cable 53) and plug it back in again.
pressure too measures too high a If the display has frozen, there is a malfunction in the I/O
high pressure in the gas card. Switch the main switch off and on - if the error persists,
circuit. replace the I/O card.
A blockage has
formed in the gas
circuit.

Possible defect:
Pressure sensor,
cable, I/O card

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Diagnostics and troubleshooting TOCII CA72TOC

Message Cause Tests or remedial action

Measured value The IR detector • The measured values in the flow of sample are constantly
> measuring continuously higher than the measuring device configuration.
range returns a signal • When option pre-dilution is installed: Stop of dilution
that is greater than function.
the specification.

Faulty CO2 concentrations • Is the gas circuit leak-tight?

adjustment measured for Check the gas-tightness of the analyzer.
(adjustment • Replace the standard solutions.
standard C1 or C2
error 1) Repeat the adjustment.
are above the
measuring range
for the IR detector.
Incorrect standard
solution

Possible defect:
Gas circuit leaking

Faulty Calculated X0 value • Is the gas circuit leak-tight?

adjustment is above the Check the gas-tightness of the analyzer.
(adjustment • Check the adjustment values in the maintenance record.
maximum value
error 2) Do one of the two record values deviate from the typical
permitted for the value?
IR detector used. • Replace the standard solutions.
Gas circuit leaking,
standard solutions

Faulty The calibration line • Verify that the solenoid valves MV1 and MV4 are functioning
adjustment slope is negative or correctly.
(adjustment zero. In the program module PRG/TEST/OUTPUTS/BINARY
error 3) CO2 concentration OUTPUTS, confirm the output SA1 for MV1 and SA4 for
measured for MV4. If the solenoid valves do not switch, replace the
standard 1 is higher relevant solenoid valve.
than that for • Have the standard solutions been prepared properly?
standard 2 • Do the two standard solutions have the same concentration?
MV1, MV4, standard • Have the standard solutions been swapped?
solutions, container • Are the standard canisters empty?
empty

Faulty KP value is smaller • Is the gas circuit leak-tight?

adjustment than 30 or greater Check the gas-tightness of the analyzer.
(adjustment than 150 • Have the standard solutions been prepared properly?
error 4) Gas circuit leaking, Replace the standard solutions.
standard solutions • Biological growth in the standard canisters.
Replace the canisters.
• Dilution option - feed rate of pump P4 deviates from the
values determined. Use the program module SERVICE/
PUMPS/P1/P4 Replace pump hose to determine the feed rate
for pump P4.

Faulty CO2 concentration • Is the IR detector OK?

adjustment < min. permitted Convey pure supply gas through the IR detector.
(adjustment CO2 value. Go to the programming module PRG/TEST/INPUTS/ANALOG
error 5) (~ -9.4 % gas card INPUTS and check whether the IR detector displays a negative
measuring range) offset.
Replace the IR detector if the frequency displayed has
dropped below 10000 Hz.

64 Endress+Hauser
TOCII CA72TOC Diagnostics and troubleshooting

Message Cause Tests or remedial action

Fault CO2 Baseline value 5 % • Once the catalyst has been replaced, the catalyst may outgas.
baseline of IR detector full This can result in an error message, particularly in low
scale value CO2-measuring ranges. The fault resolves itself after a few
New catalyst, pellets measuring cycles.
for soda-lime • Are the pellets completely discolored?
scrubbers are used Replace the pellet filling.
up, gas generator • Verify that the gas generator is functioning correctly.
malfunction, • Does the carrier gas valve allow sufficient gas through to
defective carrier gas allow for adequate flushing?
valve, leak in gas • Is the carrier gas valve sealed?
circuit, pump • Carry out a pump adjustment for pump P2.
adjustment for pump • Is the gas circuit leak-tight?
P2 is no longer up- Carry out a leakage test.
to-date

Input error Input value for C1 is • Enter the correct concentrations.

C1>C2 greater than for C2

Calibration IR signal is less • Replace the standard solution for C2. Repeat the calibration.
marked with an than 75 % of the
value for C2 from
asterisk
the last adjustment

Internal com- I/O not responding • Switch off the main switch and, after a short period of time,
fault 1 during INIT process switch it back on again. If the error persists, contact
E+H Service.

Internal com- I/O not responding • Switch off the main switch and, after a short period of time,
fault 2 during NOINIT switch it back on again. If the error persists, contact
process E+H Service.

Internal com- KEYBOARD not • Switch off the main switch and, after a short period of time,
fault 10 responding switch it back on again. If the error persists, contact
E+H Service.

Internal com- CRC error between • Switch off the main switch and, after a short period of time,
fault 20 I/O – CPU or switch it back on again. If the error persists, contact
between E+H Service.
KEYBOARD – CPU

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Maintenance TOCII CA72TOC

8 Maintenance
To ensure efficient operation of the analyzer, maintenance must be carried out at regular
intervals.

Before attempting to service the device, you must be completely familiar with the
maintenance processes and have perfectly understood the tasks involved. All the
maintenance tasks described in this chapter should only be carried out by suitably
trained specialists. Mistakes made during maintenance can result in inaccurate
operation and pose a safety hazard.

Interval Maintenance task

At least once per week • Visual inspection

• Check sample conditioning (see corresponding Operating Instructions)

At least once per month • Check feed rate of pump P1/P4 and P2
• Replace standard

Every 3 months at the latest • Clean strip and separation chamber

• Replace glass ball
• Adjust the pH sensor
• Replace pump hoses
• Check the filter pads in the ventilators and replace if necessary.

If salt quantity > 1 g/l, then • Replace acid filter

perform the following every 3 • Replace catalyst
months at the latest: • Clean combustion pipe

1 x per year • Replace filter pads in ventilators (do not clean)

• Replace membrane filter (gas filter)

The maintenance intervals depend greatly on your application. For this reason, adapt the
maintenance intervals to your specific requirements but make sure to perform these
maintenance tasks regularly!

66 Endress+Hauser
TOCII CA72TOC Maintenance

Flow chart
Use this chart as reference if you have to replace or reconnect pipes or tubes.

a0012369-en

Fig. 26: Flow chart

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Maintenance TOCII CA72TOC

Interior views

a0011861

Fig. 27: Display and operating elements

1 Main switch 16 Heated salt trap (optional)
2 Display and operating elements 17 Circuit gas flowmeter
3 USB connection 18 Dilution water pump P5 (optional)
4 Pump P2 sample analysis 19 Acid hose connector
5 Junction box 20 MV4 calibration standard changeover C1/C2
6 Compressor switch 21 MV1 wastewater/calibration standard
7 Ventilator changeover
8 Separation chamber 22 Valve for online sample/manual sample
9 Dosing valve 23 Pump P3, acid dosing
10 Ventilator 24 Pump P4, sample - dilution (optional)
11 Injection unit 25 Mixing chamber (optional)
12 Acid filter 26 Pump P1, sample - strip chamber/condensate
13 Tube furnace with catalyst extraction
14 Air outlet (filter pad) 27 Condensate hose connector
15 Combined filter (water trap) 28 Strip chamber with pH electrode
29 Sample conditioning

! WARNING
The device is energized.
Touching current-carrying components may result in injury or death.
‣ First switch off the main switch. Then open the rear of the device with the special key
provided.

68 Endress+Hauser
TOCII CA72TOC Maintenance

a0012022

Fig. 28: Rear of device

1 Peltier cooler 14 Restrictor stripping gas
2 Peltier cooler - glass insert 15 Restrictor carrier gas
3 Motor controller P1 to P6 16 Motor P1, sample - strip chamber /
4 Peltier cooler - control unit condensate drainage
5 Membrane compressor 17 Check valve
6 Motor P2 sample - analysis 18 Motor P4, sample - dilution (optional)
7 Computer unit 19 Motor P3 acid dosing
8 Power distribution 20 MV5 bypass flushing
9 Magnetic stirrer control 21 Water connection manifold
10 pH - amplifier 22 IR detector
11 MV7 carrier gas flushing 23 Leak detector contacts
12 MV3 stripping gas supply 24 Motor P5, dilution water pump (optional)
13 Gas connection block

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Maintenance TOCII CA72TOC

8.1 Cleaning the housing

Clean the analyzer housing as follows:
• Use a fluoride-free and solvent-free cleaning agent and a lint-free cloth.

8.2 Visual inspection

! WARNING
There is a risk of infection when working with wastewater!
‣ For this reason, wear protective goggles, protective gloves and protective clothing.
! CAUTION
There is a risk of injury due to hot components!
‣ Wear heat-resistant gloves when in contact with hot components in the vicinity of the
combustion furnace..
Carry out the visual inspection at least once a week:
• Check whether the measurement is operating in the standard range.
• Is the sample supply OK? To check, hold a collecting vessel under the valve and set the
valve briefly to "Manual sample". Does the sample flow out of the bypass?
• Is sample being dosed into the furnace?
• Are hoses P1 to P3 (optionally P4) leak-tight?
• Is sufficient C1 and C2 standard still available?
• Is sufficient stripping acid still available?
• If the condensate is being collected in a container, check if the container if full.
• Check the gas supply.
Pressure regulator at 2 bar (29 psi)?
Circuit gas (right flowmeter) at 0.7 to 1.2 l/min (0.18 to 0.32 gal/min)?
• Is the water supply pressure between 3 ±0.2 bar (43 ±3 psi)?
• Is the acid filter free of condensate and not severely discolored?
• Check stripping gas bubbling.
• Does the rotating slit filter rotate uniformly?
• Is a slit visible between the rotating body and the base of the chamber?

a0012724 a0012723

Fig. 29: Rotating slit filter Fig. 30: Rotating slit filter, detailed view

70 Endress+Hauser
TOCII CA72TOC Maintenance

8.3 Topping up reagents

! CAUTION
There is a risk of injury when working with reagents.
‣ Observe the warnings on the safety data sheets.
‣ Wear acid-resistant protective gloves, protective goggles and a protective laboratory
coat!
‣ In addition, adhere to the regulations applicable in your country and to your line of work
governing the handling of caustic chemicals. Rinse off splashes immediately with plenty
of water and 1 % sodium hydrocarbonate solution. Consult a physician and show him/
her the information on the canister.
Only use original canisters for measurement. No liability is accepted for damage resulting
from the use of other chemicals.
The stripping reagent and standards C1 and C2 must be topped up or replaced. To prepare
the reagents, see the "Preparing the chemicals" section.

Parent solution
• 5 000 mg/l TOC; for preparing standard solutions 1 and 2
Order number:
1000 ml (33.8 fl.oz.): CAY451-V10C01AAE
• 100 000 mg/l TOC; for preparing standard solutions 1 and 2
Order number:
1000 ml (33.8 fl.oz.): CAY451-V10C10AAE
Stripping reagent
• Stripping reagent for CA72TOC
Order number:
1000 ml (33.8 fl.oz.): CAY450-V10AAE

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Maintenance TOCII CA72TOC

8.4 Replacing the standard

This section describes how the standard solutions are replaced.

Step Display Description

1 BYPASS SCREEN stops the measuring

operation.

2 BYPASS-SCREEN Change the standard solution as

follows:
1. Remove the canister for the
standard solution.
2. Dispose of any remaining
MAINTENANCE COMPLETED ?
standard solution.
3. Rinse the canister with deionized
water.
4. Fill up the canister with new
standard solution.
5. Position the canister at the
[E] TO CONFIRM designated place.
6. Press the [E] key.

Operation starts.

If you have changed the concentration of the standard solution, enter the new concentration
in the "Measuring range data" menu item and then trigger an adjustment.

72 Endress+Hauser
TOCII CA72TOC Maintenance

8.5 Entering the concentration of the standard solution

This section describes how the concentration of the standard solution is entered.
Select the programming mode for this purpose:

Step Display Description

2 • Enter the values for STANDARD C1

and STANDARD C2.

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Maintenance TOCII CA72TOC

8.6 Service menu

The maintenance tasks are supported by the service software. This menu software is split
into four sections:

Pumps Replace hose P1/P4

Replace hose P2
Replace hose P3
Adjust P2

Calibration Analyzer adjustment

Analyzer calibration
Empty volume dosing
Adjustment pH sensor

Cleaning Screen flush

Power flush
Bypass screen
Stripper+separation
Open gas circuit
Combustion pipe
Leakage test

Filters Replace acid filter

Replace gas filter
Replace O2 filter
Replace heated filter

74 Endress+Hauser
TOCII CA72TOC Maintenance

8.7 Pumps

8.7.1 Replacing the hoses on pumps P1 and P4

This section describes how the hoses of pumps P1 and P4 are replaced and the delivery rate
is determined.
! CAUTION
Danger of crushing!
‣ Never reach into the pump head while the pump is in operation!

P1

P4

a0012483

Fig. 31: Position of pumps P1 and P4

You require the following parts:

• 10 ml graduated cylinder
• 2.5 mm Allen key
• Dosing nozzle (injector)
• Paper to absorb liquids
• Collecting vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid
• Silicone grease

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Maintenance TOCII CA72TOC

2
6

7
1

8
a0012364

Fig. 32: Pump P1

1 Pump retainer 5 Motor

2 Pump head 6 Condensate hose (BK-BK) 0.76 mm (0.03")
ID
3 Hose cassette (sample hose) 7 Sample hose (VT-WH) 2.79 mm (0.11") ID
4 Hose cassette (condensate hose) 8 Adjusting screw

Pump P1: The sample hose to the strip chamber has an internal diameter of 2.79 mm (0.11")
with violet-white (VT-WH) color coding and the condensate drain hose has an ID of
0.76 mm (0.03") with black-black (BK-BK) color coding.
Pump P4 (only for "With predilution" version): sample hose to the static mixer 2.79 mm
(0.11") with VT-WH color coding.

Step Display Description

76 Endress+Hauser
TOCII CA72TOC Maintenance

Step Display Description

2 ! WARNING
There is a risk of infection when
working with wastewater!
‣ Wear protective gloves, goggles
and protective clothing.

Press the [E] key.

The strip and separation chambers

are flushed with pressurized water.

3 REPLACE HOSE P1/4 1. Set the sample valve to manual

sampling.
2. To empty the pump hose and the
strip chamber, place a collecting
SWITCH VALVE TO MANUAL SAMPLING, vessel under the hose connection
for manual sampling.
PUT COLLECTING VESSEL BELOW
3. Press the [E] key.

[E] TO CONFIRM

4 1. First open the hose cassettes for

pump 1.
2. Now open the hose cassette for
pump 4.
3. Drain the strip chamber.
4. Press the [E] key.

For versions "with predilution":

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Maintenance TOCII CA72TOC

Step Display Description

For versions "without predilution": 1. Open the hose cassette for

pump 1.
2. Drain the strip chamber.
3. Press the [E] key.

5 REPLACE HOSE P1/4 In areas with a low amount of dust:

Grease the new hoses with a light
coating of silicone grease.
1. Hold paper under the strip
chamber and mixer hose
connection.
REPLACE PUMP HOSE
2. Release the pump hoses
(items 6 + 7) from the
connections.
3. Replace the hoses.
4. Press the [E] key.

[E] TO CONFIRM
Continue with Step 6 for versions
"with predilution".
Continue with Step 14 for versions
"without predilution".

6 For versions "with predilution": 1. Lock the hose cassettes in place in

the retainer.
REPLACE HOSE P1/4 2. Make sure the hose cassette is
seated correctly in the retainer.
3. Connect the P1 and P4 suction
sides.
CLOSE HOSE CASSETTE(S) P1
CLOSE HOSE CASSETTE P4 4. Press the [>] key to fill the hose
with sample.
CONNECT LOWER HOSES
5. Check the drip pattern (even feed
FILL HOSE WITH SAMPLE rate).
You can now check the contact
pressure of the hose cassette:
[>] START/STOP PUMP 4 (100%)
1. Release the adjusting screw
[E] TO CONFIRM (item 8) until no more medium is
conveyed.
2. Now tighten the adjusting screw
until the unit starts to pump
medium again. Even medium
delivery should be visible across
all pump heads.
3. Tighten the adjusting screw one
revolution.

78 Endress+Hauser
TOCII CA72TOC Maintenance

Step Display Description

7 REPLACE HOSE P1/4 If required, you can measure the

capacity of pump hose P4.
1. Secure or hold the 10 ml
graduated cylinder close to
pump P4.
2. Guide hose P4 into the graduated
cylinder.
IF REQUIRED, MEASURE CAPACITY OF HOSE P4
3. Press the [>] key so pump P4 is
PREVIOUS VOLUME DELIVERED x.x ml operating at 100% capacity for
60 s.
[>] START/STOP PUMP 4 (60sec)

[E] TO CONFIRM

You can enter the new value after

60 seconds.
The value typically lies between
5.5 and 7 ml (0.18 and 0.24 fl.oz).

REPLACE HOSE P1/4 The amount entered is displayed so

you can check it is correct.
Press the [E] key.

NEW VOLUME DELIVERED x.x ml

[>] START/STOP PUMP 4 (60sec)

[E] TO CONFIRM

8 REPLACE HOSE P1/4 1. Seal the strip chamber inlet with

a separate plug (e.g. plug for leak
test).
2. Connect hose P4 at the pressure
SHUT STRIP CHAMBER INLET WITH side.
SEPARATE PLUG 3. Press the [E] key.
CONNECT HOSE P4

[E] TO CONFIRM

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Maintenance TOCII CA72TOC

Step Display Description

9 1. Use the dosing nozzle of the

injector to expand the hose end of
the condensate hose.
2. Connect the suction side of the
condensate hose and place the
pressure side of the condensate
hose into a glass containing
water.
3. Press the [>] key to fill the
sample hose with sample.
4. Check the drip pattern of the
sample hose and check the air
bubbles in the glass of water
(even feed rate).
You can now check the contact
pressure of the hose cassette:
1. Release the adjusting screw
(item 8) until no more medium is
conveyed (air bubbles).
2. Now tighten the adjusting screw
until the unit starts to pump
medium again. Even medium
delivery should be visible across
all pump heads.
3. Tighten the adjusting screw one
revolution.
4. Reconnect the pressure side of
the condensate hose.

10 If required, you can measure the

capacity of pump hose P1.
1. Secure or hold the 10 ml
graduated cylinder close to
pump P1.
2. Guide hose P1 into the graduated
cylinder.
3. Press the [>] key so pump P1 is
operating at 100% capacity for
60 s.

You can enter the new value after

60 seconds.
The value typically lies between
5.5 and 7 ml (0.18 and 0.24 fl.oz).

80 Endress+Hauser
TOCII CA72TOC Maintenance

Step Display Description

Press the [E] key.

11 1. Connect hose P1 at the pressure

side.
2. Press the [E] key.

12 REPLACE HOSE P1/4 1. Set the manual valve on the

bypass to sampling.
2. Pump the sample out of the
bypass with pump P4 until
SWITCH VALVE TO BYPASS dilution.
3. Press the [E] key.
FILL HOSE WITH SAMPLE

[>] START/STOP PUMP 4 (100%)

[E] TO CONFIRM

13 REPLACE HOSE P1/4 Stabilize dilution

Continue with Step 18.

XXX
STABILIZE DILUTION

Endress+Hauser 81
Maintenance TOCII CA72TOC

Step Display Description

14 For versions "without predilution": 1. Lock the hose cassettes in place in

the retainer.
2. Make sure the hose cassette is
seated correctly in the retainer.
3. Use the dosing nozzle of the
injector to expand the hose end of
the condensate hose.
4. Connect the P1 suction side.
5. Set the sample tap to bypass.
6. Place the pump side of the
condensate hose into a glass of
water.
7. Press the [>] key to fill the hose
with sample.
8. Check the drip pattern of the
sample hose and check the air
bubbles in the glass of water
(even feed rate).
You can now check the contact
pressure of the hose cassette:
1. Release the adjusting screw
(item 8) until no more medium is
conveyed (air bubbles).
2. Now tighten the adjusting screw
until the unit starts to pump
medium again. Even medium
delivery should be visible across
all pump heads.
3. Tighten the adjusting screw one
revolution.
4. Reconnect the pressure side of
the condensate hose.

15 If required, you can measure the

capacity of pump hose P1.
1. Secure or hold the 10 ml
graduated cylinder close to
pump P1.
2. Guide hose P1 into the graduated
cylinder.
3. Press the [>] key so pump P1 is
operating at 100% capacity for
60 s.

The value typically lies between

5.5 and 7 ml (0.18 and 0.24 fl.oz).

82 Endress+Hauser
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Step Display Description

Enter the new feed rate.

Press the [E] key.

16 1. Connect hose P1 at the pressure

side.
2. Press the [E] key.

17 1. Set the manual valve to bypass.

2. Using pump P1, pump the sample
as far as the strip chamber.
3. Press the [E] key.

18 Automatic filling of the strip

chamber, conditioning of the strip
chamber with active acid dosing

Endress+Hauser 83
Maintenance TOCII CA72TOC

8.7.2 Changing the hose of pump P2

This section describes how the hose of pump P2 is replaced. The following service menus are
automatically started when this service menu finishes:
1. Adjusting pump P2
2. Empty volume dosing
! CAUTION
Danger of crushing!
‣ Never reach into the pump head while the pump is in operation!

a0012484

Fig. 33: Position of pump P2

You require the following parts:

• 10 ml graduated cylinder
• 2.5 mm Allen key
• Dosing nozzle (injector)
• Paper to absorb liquids
• Collecting vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid
• Silicone grease

84 Endress+Hauser
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2 1
3
a0014230

1 Pump retainer 4 Adjusting screw

2 Pump head 5 Hose cassette
3 Sample hose (BK-BK) 0.76 mm (0.03") ID 6 Motor

Pump P2: Pumps sample from the separation chamber into the furnace. Hose: (BK-BK)
0.76 mm (0.03")

Step Display Description

2 ! WARNING
There is a risk of infection when
working with wastewater!
‣ Wear protective gloves, goggles
and protective clothing.

Press the [E] key.

Endress+Hauser 85
Maintenance TOCII CA72TOC

Step Display Description

3 REPLACE HOSE P2 The hose is drained automatically.

XX
PLEASE WAIT

PUMP CONVEYS BACKWARDS

[E] TO CONFIRM

4 REPLACE HOSE P2 1. Open the cover of the separation

chamber.
2. Empty the separation chamber
with the syringe (part of the
scope of supply).
EMPTY SEPARATION CHAMBER USING NOZZLE! 3. Press the [E] key.

[E] TO CONFIRM

5 REPLACE HOSE P2 In areas with a low amount of dust:

Grease the new hoses with a light
coating of silicone grease.
1. Release the hose at the injection
REPLACE PUMP HOSE unit and at the separation
chamber.
2. Disengage the hose cassette.
3. Change the hose.
4. Use the dosing nozzle of the
injector to expand the hose end.
5. Engage the hose cassette.
[E] TO CONFIRM 6. Press the [E] key.

86 Endress+Hauser
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Step Display Description

6 1. Seal the separation chamber.

2. Connect the hose at the suction
side.
3. Start the service menu "Adjust
pump P2" or press the [E] key to
quit the service menu.

7 1. Press the [>] key to fill the hose

with sample.

FILL HOSE WITH SAMPLE 2. Check the drip pattern (even feed
rate).
If a steady flow of medium does not
occur, check the contact pressure of
the hose cassette:
1. Release the adjusting screw
(item 4) until no more medium is
[>] START/STOP PUMP 2 (100%) conveyed.
[E] TO CONFIRM 2. Now tighten the adjusting screw
until the unit starts to pump
medium again. Even medium
delivery should be visible across
all pump heads.
3. Tighten the adjusting screw one
revolution.
Press the [E] key.

8 1. Connect the hose P2 to the

injection unit
2. Press the [E] key.
Measuring operation is started
automatically.

The accuracy of the feed rate of pump P2 affects the measurement result. For this
reason, start the following service menus in the order indicated once the pump hose has
been replaced:
1."Adjust pump 2"
2."Empty volume dosing"
Please also note that the hoses are subject to deterioration in the first hours of
operation. For this reason, repeat these maintenance tasks after 24 hours.

Endress+Hauser 87
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8.7.3 Replacing the hose on pump P3

This section describes how the hose of pump P3 is replaced.
! CAUTION
Danger of crushing!
‣ Never reach into the pump head while the pump is in operation!
! CAUTION
Risk of injury due to acid
‣ Wear acid-resistant protective gloves, protective goggles and protective clothing!
NOTICE
Failure to comply may result in incorrect measurements
‣ No medium containing TOC should enter the acid feeder!

a0012485

Fig. 34: Position of pump P3

You require the following parts:

• Acid-resistant protective gloves, protective goggles and protective clothing
• 10 ml graduated cylinder
• 2.5 mm Allen key
• Dosing nozzle (injector)
• Paper to absorb liquids
• Collecting vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid
• Silicone grease

88 Endress+Hauser
TOCII CA72TOC Maintenance

3
4

2
5

a0012368

Fig. 35: Pump P3

1 Pump retainer 4 Motor

2 Pump head 5 Acid hose (BK-BK) 0.76 mm (0.03") ID
3 Hose cassette 6 Adjusting screw

Pump P3: Pumps acid from the feeder tank into the strip chamber.
Hose: (BK-BK) 0.76 mm (0.03")

Step Display Description

2 ! CAUTION
Risk of injury due to acid!
‣ Wear acid-resistant protective
gloves, protective goggles and
protective clothing. Rinse areas
splashed with acid immediately
with plenty of water and 1 %
sodium hydrocarbonate solution.
Consult a physician and show
him/her the information on the
canister.

Press the [E] key.

The strip and separation chambers
are flushed with pressurized water.

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Step Display Description

3 REPLACE HOSE P3 1. Release the hose connection from

pump P1 to the strip chamber.

EMPTY STRIP CHAMBER BY 2. Have a vessel at the ready to

DISCONNECTING HOSE CONNECTION OF collect the liquid.
SAMPLE PUMP P1 AT THE STRIP CHAMBER 3. Drain the strip chamber.
PLACE VESSEL BELOW TO COLLECT 4. Press the [E] key.
CONTENT OF STRIP CHAMBER

[E] TO CONFIRM

4 REPLACE HOSE P3 Caution! Acid!

1. Remove the acid suction hose
DANGER! ACID from the acid cistern and place
the end in a collecting vessel.
REMOVE ACID SUCTION HOSE FROM 2. Release the hose cassette.
ACID FEEDER AND PLACE VESSEL
BELOW TO COLLECT ACID 3. Make sure that the acid runs back
into the collecting vessel.

RELEASE HOSE CASSETTE P3 AND EMPTY NOTICE

ACID LINE Failure to comply may result in
incorrect measurements
‣ No medium containing TOC
should enter the acid feeder!
[E] TO CONFIRM
4. Press the [E] key.

5 In areas with a low amount of dust:

Grease the new hoses with a light
coating of silicone grease.
1. Release the pump hose from the
connections.
2. Change the hose.
3. Press the [E] key.

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Step Display Description

6 REPLACE HOSE P3 1. Connect the hose of pump P1 to

the strip chamber.
2. Press the [E] key.

CONNECT SAMPLE HOSE PUMP P1

TO STRIP CHAMBER

[E] TO CONFIRM

7 1. Rinse the suction hose of the acid

pump.
2. Guide the suction tube into the
acid feeder tank.
3. Insert the hose cassette into P3
and connect the hose to the hose
connector.
4. Use the dosing nozzle of the
injector to expand the hose end.
5. Press the [>] key until acid enters
the strip chamber.
6. Make sure medium is being
conveyed evenly in the suction
hose.
You can now check the contact
pressure of the hose cassette:
1. Release the adjusting screw
(item 6) until no more medium is
conveyed.
2. Now tighten the adjusting screw
until the unit starts to pump
medium again. Even medium
delivery should be visible across
all pump heads.
3. Tighten the adjusting screw one
revolution.

Continue with Step 8 for versions

"with predilution".
Continue with Step 10 for versions
"without predilution".

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Step Display Description

8 REPLACE HOSE P3 Dilution stabilizes for 120 s.

XXX
STABILIZE DILUTION

9 REPLACE HOSE P3

XX
FILL HOSE WITH SAMPLE

10 REPLACE HOSE P3 Automatic filling of the strip

chamber, conditioning of the strip
chamber with active acid dosing

XX Measuring operation is started

automatically.

FILL STRIP AND SEPARATION CHAMBERS

92 Endress+Hauser
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8.7.4 Adjusting pump P2

This section describes how the feed rate of pump P2 is determined. The "Empty volume
dosing" service menu is started automatically when this service menu finishes:
! CAUTION
Danger of crushing!
‣ Never reach into the pump head while the pump is in operation!

a0012484

Fig. 36: Position of pump P2

You require the following parts:

• 10 ml graduated cylinder
• 2.5 mm Allen key
• Dosing nozzle (injector)
• Paper to absorb liquids
• Collecting vessel with volume of approx. 150 ml (5 fl.oz) to collect liquid

Endress+Hauser 93
Maintenance TOCII CA72TOC

2 1
3
a0014230

Fig. 37: Pump P2

1 Pump retainer 4 Adjusting screw

2 Pump head 5 Hose cassette
3 Sample hose (BK-BK) 0.76 mm (0.03") ID 6 Motor

Step Display Description

2 ! CAUTION
There is a risk of infection when
working with wastewater!
‣ For this reason, wear protective
goggles, protective gloves and
protective clothing.

Press the [E] key.

94 Endress+Hauser
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Step Display Description

3 1. Release hose P2 at the dosing

needle.
2. Hold a collecting vessel under the
hose.
3. Start pump P2 with the [>] key.
4. Fill the hose until an even
amount of sample exits the hose.
No air bubbles should be
conveyed. Make sure that even
dosage takes place over all the
rollers of the pump head.
5. Stop the pump as soon as a steady
flow of medium is pumped.
If a steady flow of medium does not
occur, you can check the contact
pressure of the hose cassette:
1. Release the adjusting screw
(item 4) until no more medium is
conveyed.
2. Now tighten the adjusting screw
until the unit starts to pump
medium again. Even medium
delivery should be visible across
all pump heads.
3. Tighten the adjusting screw one
revolution.

4
1. Place a graduated cylinder
underneath the end of the dosing
tube.
2. Press the [E] key to start time-
controlled dosage.

5 Pump P2 pumps at 100 % for

10 minutes.

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Maintenance TOCII CA72TOC

Step Display Description

6 ADJUSTMENT PUMP 2 Enter the delivery volume

determined.
The value typically lies between
ENTER ml ? 8.5 and 9.5 ml (0.29 and 0.32 fl.oz).

[E] TO CONFIRM

7 Press the [E] key.

8 1. Connect hose P2.

2. Press the [E] key (the "Empty
volume dosing" service menu is
started).

The accuracy of the feed rate of pump P2 affects the measurement result. For this
reason, the "Empty volume dosing" service menu is started once pump P2 has been
adjusted.

96 Endress+Hauser
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8.7.5 Cleaning dilution water pump P5

If you use deionized water as the dilution medium, pump P5 only has to be cleaned as
part of the annual maintenance work performed by Endress+Hauser Service.
If you are using drinking water as the dilution medium, the maintenance intervals may
be reduced depending on the water hardness level. In this case, contact Endress+Hauser
Service

a0014102

Fig. 38: Position of pump P5

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8.8 Adjusting

8.8.1 Adjusting the analyzer

This section describes how the analyzer is adjusted.
The analyzer is adjusted using two-point adjustment. Two different standard solutions are
measured for this purpose. These standard solutions are connected in the analyzer.
Adjustment procedure:
1. The basic line is measured.
2. The analyzer measures the concentration of standard C1.
3. The basic line is measured.
4. The analyzer measures the concentration of standard C2.
5. The offset X0 and the slope Kp are calculated from these values.

Measuring signal = CO2(C) = CO2(dose) - CO2(base line)

a0012547-en

Fig. 39: Calculation of the measuring signal

CO2(C2) - CO2(C1)
X0 = CO2(C1) - C1
(C2 - C1)
a0012549

Calculation of the offset X0

C2
Kp = actual dosing volume 0.3125
CO2(C2) - X0
a0012548-en

Fig. 40: Calculation of the standardized slope Kp

Measured signal

Kp

X0
Concentration
C1 C2
a0012550-en

Fig. 41: Adjustment curve

CO2(C1) = CO2 concentration of the measurement of standard C1.

CO2(C2) = CO2 concentration of the measurement of standard C2.

The offset and the reciprocal standardized slope of the adjustment curve (measuring signal
per concentration) are saved in the maintenance record log under ADJUSTMENT
CONSTANTS.
Analyzer adjustment can be started in three ways:
• Activated manually
• Activated remotely
• Activated automatically

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Manually activated adjustment

Step Display Description

Remotely activated adjustment

Adjustment can be triggered by a floating contact. Use input 2 of the "binary in" terminal strip
for this purpose.

1 1 +24VDC
1 GND
I
2 2
1 +24VDC
1
2
2 GND
II
2 1 +24VDC
1 3 GND
binary out

2
III

2 1 +24VDC
binary in 2
4 GND
1
IV

2 1 +24VDC
2 5 GND
1 +24VDC
0/4-20 +
2 6 GND
40
mA - 1 +24VDC
2 7 GND
0/4-20 +
41 1 +24VDC
mA -
8 GND
2

RS 232

a0011911

Fig. 42: Signal connection

1 Calibration, external activation 5 Not assigned

2 Adjustment, external activation 6 Not assigned
3 Screen flush, external activation 7 Standby, external activation
4 Power flush, external activation 8 Channel switchover, external activation
(optional)

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Automatically activated adjustment

The analyzer can be adjusted automatically.
Select the programming mode for this purpose:

Step Display Description

2 • For CAL./ADJUST. n DAYS, specify

the number of days after which an
adjustment is to be performed. It is
generally not necessary to select
more than one adjustment every
three days.
• Enter the value 2 for CAL./
ADJUSTM.
Value 1 = Calibration
Value 2 = Adjustment

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8.8.2 Calibrating the analyzer

This section describes how the analyzer is calibrated.
The analyzer checks the current recovery by measuring the standard solution C2. In contrast
to adjustment, the adjustment constants are not changed.
The standard solution C2 is connected to the analyzer.
Analyzer calibration can be started in three ways:
• Activated manually
• Activated remotely
• Activated automatically
Manually activated calibration

Step Display Description

Remotely activated calibration

Calibration can be triggered by a floating contact. Use input 1 of the "binary in" terminal strip
for this purpose.

1 1 +24VDC
1 GND
I

2 2
1 +24VDC
1
2
2 GND
II

2 1 +24VDC
1 3 GND
binary out

2
III

2 1 +24VDC
4
binary in

1 2 GND
IV

2 1 +24VDC
2 5 GND
1 +24VDC
0/4-20 +
2 6 GND
40
mA - 1 +24VDC
2 7 GND
0/4-20 +
41 1 +24VDC
mA -
8 GND
2

RS 232

a0011911

Fig. 43: Signal connection

1 Calibration, external activation 5 Not assigned

2 Adjustment, external activation 6 Not assigned
3 Screen flush, external activation 7 Standby, external activation
4 Power flush, external activation 8 Channel switchover, external activation
(optional)

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Automatically activated calibration

The analyzer can be calibrated automatically.
Select the programming mode for this purpose:

Step Display Description

2 • For CAL./ADJUST. n DAYS, specify

the number of days after which a
calibration is to be performed. It is
generally not necessary to select
more than one calibration every
three days.
• Enter the value 1 for CAL./
ADJUSTM.
Value 1 = Calibration
Value 2 = Adjustment

Analog value output during calibration (menu SETTING -BASIC DATA - DC OUT
CALIBRATION)
• 0: in the event of a calibration, the last measured value is transmitted to the analog
output. This output is set to "Hold" until the calibration value has been determined. The
calibration value is then transmitted to the analog output until a new measured value
has been determined for the current sample.
• 1: signal output in mA is held (last measured value) until a new measured value has
been determined.

During calibration, relay IV (OPERATION CHECK) is opened until a new measured value
is available in measuring mode. If the analog output is used for control purposes, this
OPERATION CHECK signal can be used to declare the analog output as invalid.

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8.8.3 Empty volume dosing

Use this service menu to determine the dead volume of pump P2 from the separation
chamber to the end of the capillary.

a0012487

Fig. 44: Position

Step Display Description

2 The hose of pump P2 is drained.

3 The pump pumps automatically in the

direction of the capillary.
Pumping stops if:
a) A drop is detected or
b) The system times out after 180 s.

In the event of a), continue with

Step 4.
In the event of b), continue with
Step 6.

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Step Display Description

4 The new volume value determined

appears on the display. The value,
including the volume and time, is
entered in the EMPTY VOLUME
DOSING log.
The value determined is saved in the
EMPTY VOLUME P2 [μl] parameter.

5 Measuring operation is started once you confirm with the [E] key.
"Empty volume dosing" ends.

6 The system has timed out.

Determine the empty volume
manually.

The service is restarted and the

automatic determination function is
disabled.

Empty volume dosing can now be

carried out manually.

7 The pump is drained.

8 Start the pump with the [E] key.

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Step Display Description

9 Stop the pump with the [E] key when

the first drop falls.

10 The new volume value determined

appears on the display. The value,
including the volume and time, is
entered in the EMPTY VOLUME
DOSING log.
The value determined is saved in the
EMPTY VOLUME P2 [μl] parameter.

11 Measuring operation is started once you confirm with the [E] key.
"Empty volume dosing" ends.

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8.8.4 Adjustment pH sensor

This section describes how to remove and install the pH sensor, and how to perform
two-point adjustment on the pH sensor.

a0012478

Fig. 45: Position of the sensor

To adjust the pH sensor, you require:

• Deionized water
• Buffer solution pH = 4.00
• Buffer solution pH = 7.00
• Paper towels to absorb liquid
• Vessel to collect liquids

a0012176

Fig. 46: Strip chamber and separation chamber

1 pH sensor
2 Cover
3 Thread adapter nut
4 Strip chamber

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Step Display Description

2 ADJUSTMENT pH SENSOR 1. Release the thread adapter nut

(3) on the strip chamber (4).
2. Remove the cover (2) with the
pH sensor (1) from the strip
RELEASE COVER OF STRIP CHAMBER chamber.
3. Press the [E] key.
CAREFULLY REMOVE SENSOR

[E] TO CONFIRM

3 1. Rinse the sensor with deionized

water.
2. Hold the sensor in the buffer
solution pH = 4.00.
3. Press the [E] key.

4 ADJUSTMENT pH SENSOR 1. Wait until the measured value

stabilizes (a bar appears to the
right of the measured value).
2. Press the [E] key.

MEASURED VALUE X.XX

[E] TO CONFIRM

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Step Display Description

5 1. Rinse the sensor with deionized

water.
2. Hold the sensor in the buffer
solution pH = 7.00.
3. Press the [E] key.

6 ADJUSTMENT pH SENSOR 1. Wait until the measured value

stabilizes (a bar appears to the
right of the measured value).
2. Press the [E] key.

Calculation of the calibration values.

Typical slope value: between 55 mV/
decade and 58 mV/decade

MEASURED VALUE X.XX

[E] TO CONFIRM

7 ADJUSTMENT pH SENSOR 1. Put the pH sensor into the strip

chamber.
2. Screw the cover of the strip
chamber closed hand-tight.
3. Press the [E] key.
RE-INSERT pH-SENSOR
Operation starts.

[E] TO CONFIRM

The following appears on the display if the adjustment failed:

108 Endress+Hauser
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Step Display Description

The adjustment constants are not

accepted.
• Check the buffer solutions.
• Check the sensor or
• Replace the sensor.
Repeat the adjustment.

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8.9 Cleaning

8.9.1 Screen flush

In the version with the pipe back flushing option, water is supplied via the solenoid valve
MV1. This means that, in addition to the sample conditioning system, the pipe is back-
flushed all the way to the bypass screen.

a0012726

Fig. 47: Position of the screen

Screen flushing runs automatically after startup, and can be started in three ways:
• Activated manually
• Activated remotely
• Activated automatically
Manual activation of screen flush

Step Display Description

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Remote activation of screen flush

The screen flush can be triggered using a potential-free contact. Use input 3 of the "binary
in" terminal strip for this purpose.

1 1 +24VDC
1 GND

I
2 2
1 +24VDC
1
2
2 GND

II
2 1 +24VDC
1 3 GND

binary out
2

III
2 1 +24VDC
4

binary in
1 2 GND

IV
2 1 +24VDC
2 5 GND
1 +24VDC
0/4-20 +
2 6 GND
40
mA - 1 +24VDC
2 7 GND
0/4-20 +
41 1 +24VDC
mA -
8 GND
2

RS 232

a0011911

Fig. 48: Signal connection

1 Calibration, external activation 5 Not assigned

2 Adjustment, external activation 6 Not assigned
3 Screen flush, external activation 7 Standby, external activation
4 Power flush, external activation 8 Channel switchover, external activation
(optional)

Automatic activation of screen flush

The screen flush can be triggered automatically.
Select the programming mode for this purpose:

Step Display Description

2 • For SCREEN FLUSH

n/Day, enter the number of flushes
per day. The factory setting is two
screen flushes per day.

Operation starts automatically on completion of the screen flush process.

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8.9.2 Power flush

During a power flush, the strip chamber and separation chamber are flushed with the
connected pressurized water via solenoid valve MV2.

a0012478

Fig. 49: Position of the strip and separation chamber

Power flushing runs automatically after startup, and can be started in three ways:
• Activated manually
• Activated remotely
• Activated automatically
Manual activation of power flush

Step Display Description

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Remote activation of power flush

The power flush can be triggered with a potential-free contact. Use input 4 of the "binary in"
terminal strip for this purpose.

1 1 +24VDC
1 GND

I
2 2
1 +24VDC
1
2
2 GND

II
2 1 +24VDC
1 3 GND

binary out
2

III
2 1 +24VDC
4

binary in
1 2 GND

IV
2 1 +24VDC
2 5 GND
1 +24VDC
0/4-20 +
2 6 GND
40
mA - 1 +24VDC
2 7 GND
0/4-20 +
41 1 +24VDC
mA -
8 GND
2

RS 232

a0011911

Fig. 50: Signal connection

1 Calibration, external activation 5 Not assigned

2 Adjustment, external activation 6 Not assigned
3 Screen flush, external activation 7 Standby, external activation
4 Power flush, external activation 8 Channel switchover, external activation
(optional)

Automatic activation of power flush

The power flush can be triggered automatically.
Select the programming mode for this purpose:

Step Display Description

2 • For POWER FLUSH

n/Day, enter the number of flushes
per day. The factory setting is two
power flushes per day.

Operation starts automatically on completion of the power flush process.

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8.9.3 Bypass screen

This section describes how the bypass screen is cleaned manually.

a0012489

Fig. 51: Sample conditioning

1 Upper thread adapter nut 5 Vent

2 Bypass elbow 6 Bypass screen
3 Lower thread adapter nut 7 O-ring
4 Bypass screen housing 8 O-ring

You require the following parts:

• Bottle brush
• Paper towels

Step Display Description

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Step Display Description

2 BYPASS-SCREEN ! WARNING
There is a risk of infection when
working with wastewater!
‣ Wear protective gloves, goggles
and protective clothing.
MAINTENANCE COMPLETED ?
Clean the bypass screen as follows:
1. Shut off the supply of wastewater
(external sample supply).
2. Set the "Online sample/manual
sample" valve to "Manual sample".
Drain the bypass line. Set the
valve back to the previous
[E] TO CONFIRM position.
3. Release the lower and upper
thread adapter nut (items 1 + 3).
4. Remove the bypass elbow
(item 2).
5. Remove the bypass screen.
6. Clean the bypass screen and the
housing with a brush.
7. Unscreen the vent and open it.
Clean the vent and make sure the
bead is able to move freely.
8. Insert the parts again in the
reverse order.
Make sure that the O-rings
(items 7 and 8) are undamaged
and are correctly positioned.
9. Switch the supply of wastewater
back on.
10. Press the [E] key.

Operation starts.

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8.9.4 Strip and separation chamber

This section describes how to manually clean the strip and separation chamber and replace
the glass ball.

a0012478

Fig. 52: Position of the strip and separation chamber

You require the following parts:

• 4 mm Allen key
• Injector (part of the scope of supply)
• Glass ball
• Soft brush
• Paper towels to absorb liquid
• Vessel with volume of approx. 150 ml (5 fl. oz) to collect liquid
• Needle-nosed pliers

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a0012343

Fig. 53: Strip and separation chamber

1 pH sensor 9 Separation chamber cover

2 Strip chamber cover 10 Magnetic stir bar
3 Strip chamber thread adapter nut 11 Glass ball
4 Coupling 12 Glass frit
5 Strip chamber 13 O-ring
6 Coupling (drain) 14 Coupling (stripping gas connection)
7 Separation chamber thread adapter nut 15 Capillary
8 Separation chamber 16 Knurled head screw
17 Seal

Step Display Description

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Step Display Description

2 ! WARNING
There is a risk of infection when
working with wastewater!
‣ Wear protective gloves, goggles
and protective clothing.

Press the [E] key.

3 The strip and separation chamber are

automatically flushed with
pressurized water for 10 s.

4 1. Have a vessel at the ready to

collect the liquid.
2. Release the hose connection of
pump P1 at the strip chamber.
3. Hold the vessel in place and drain
the strip chamber.
4. Absorb any drops of water with
paper towels.
5. Press the [E] key.

5 1. Release the thread adapter nut

(item 3) on the strip chamber.
2. Release the cable of the pH
sensor.
3. Remove the cover (item 2) with
the pH sensor (item 1) from the
strip chamber (item 5).
4. Release the coupling (item 14)
and remove the coupling and the
glass frit (item 12).
5. Release the coupling (item 6) and
take off the hose coupling.
6. Release the thread adapter nut
(item 7) and remove the cover
(item 9).

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Step Display Description

7. Use the pliers to remove the magnetic stir bar (item 10) from the separation chamber (item 8).
8. Empty the separation chamber (item 8) with the injector (withdrawn by suction).
9. Connect the empty injector to the suction needle for the sample (connection P2).
10. Using the injector, inject air quickly and force the glass ball out of the bore hole. To make it
easier to remove the glass ball, you can release the coupling (item 4) and release the
separation chamber from the strip chamber.
11. Clean the chambers with a soft brush. In the event of severe fouling, you can separate the strip
chamber and separation chamber from one another by releasing the securing screw. For
complete removal, you must disconnect the connector of the magnetic stirrer controller.
12. Clean the pH sensor (see the Brief Operating Instructions of the pH sensor).
13. Insert a new glass ball.
14. Insert the magnetic stir bar. The thin shaft points upwards.
15. Release the knurled head screw (item 16) and remove the capillary (item 15).
16. Insert a new capillary. Slide in the capillary as far as it will go.
Ensure that the seal (item 17) is seated correctly in the knurled head screw. Tighten the
knurled head screw.
17. Fit the hose (P2) onto the capillary.
18. Put the cover on the separation chamber and tighten the thread adapter nut hand-tight.
19. Put the drain pipe onto the coupling and screw the coupling (item 6) closed.
20. Insert the pH sensor and connect the cable.
21. Screw the thread adapter nut hand-tight.
22. Clean the glass frit or replace it. Reinstall the glass frit, the O-ring (item 13) and the coupling.
23. Press the [E] key.

6 1. Connect the hose of pump P1 to

the strip chamber.
2. Press the [E] key.

7 POWER FLUSH The strip and separation chamber are

automatically flushed with
pressurized water for 180 s.
XX Measuring operation then starts
automatically.

FILL STRIP AND SEPARATION CHAMBERS

Adjust the pH sensor after cleaning the strip and separation chamber (see the
"Adjusting the pH sensor" section).

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8.9.5 Opening the gas circuit

This section describes how the dosing head (capillary) is cleaned or replaced.
The furnace temperature is not reduced. The system continues to perform sample
conditioning (stripping).

a0012498

Fig. 54: Position of the dosing unit

You require the following parts:

• Damp cloth

5
4
1

a0012492

Fig. 55: Dosing

1 Red screw plug
2 Capillary
3 O-ring
4 O-ring
5 Dosing head

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Step Display Description

2 OPENING THE GAS CIRCUIT Clean the needle as follows:

1. Remove the hose P2 from the
capillary of the dosing head.
2. Release the red screw plug (item
1).
MAINTENANCE COMPLETED ?
3. Remove the dosing head (item 5).
4. Using a damp cloth, remove the
salt residue on the capillary or
replace the capillary.
When installing the
capillary (item 2), ensure
that the capillary is
[E] TO CONFIRM protruding from the bottom
of the dosing head by
approx. 10 mm (0.4").
5. Check the O-ring (item 4), and
also check the O-ring (item 3) if
replacing the capillary.
6. Insert the dosing head and
tighten the red screw plug.
7. Fit the hose P2 onto the capillary.
8. Press the [E] key.

Operation starts.

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8.9.6 Combustion pipe

This section describes how the combustion pipe is cleaned and replaced, or how the entire
furnace is replaced.
The furnace heating system is switched off.

a0012530

Fig. 56: Position of the furnace

You require the following parts:

• Auxiliary tool for the combustion pipe insert
• Crucible tongs
• Heat-resistant gloves
• Dust mask FFP3

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a0012387

Fig. 57: Furnace

1 Dosing head 6 Knurled head screw with support and sealing

ring
2 Red screw plug with O-ring 7 Clamp screw
3 Furnace cover 8 Optional heated salt trap
4 Thread adapter nut 9 Safety guard
5 Furnace outlet with O-ring 10 Combustion pipe

Step Display Description

1 ! CAUTION
Inhalation of catalyst dust poses a
health hazard.
‣ Wear a breathing mask when
replacing the catalyst.

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Step Display Description

2 COMBUSTION PIPE ! CAUTION

Contact with hot parts of the
combustion furnace may cause
injury!
‣ Use heat-resistant gloves.

REMOVE HOSE P2 FROM FURNACE

The power supply for the combustion
furnace is switched off. The furnace
cools down.
1. Release the hose at the dosing
head (item 1).
2. Press the [E] key.
[E] TO CONFIRM

3 COMBUSTION PIPE ! CAUTION

Contact with hot parts of the
combustion furnace may cause
injury!
‣
TEMPERATURE = XXX °C
Use heat-resistant gloves.

If the insert in the combustion

pipe is removed when very hot
(over 300 °C), cracks may form
in the insert and the
OPEN FURNACE combustion pipe if they cool
down too quickly. This results in
a higher basic line and has a
[E] TO CONFIRM negative impact on the
operation of the measuring
device.
1. If a heated salt trap is installed,
release the hose connection and
the electrical collection at the
heated salt trap.
2. Remove the safety guard.
3. Swivel the furnace outwards.
4. Pull the heated salt trap down
from the furnace outlet by
turning it gently back and forth.
5. Swivel the furnace back in and
lock it.
6. When the temperature has
dropped to approx. 300 °C,
slacken the lower knurled head
screw (item 6).
7. Allow the furnace to cool to
below 50 °C (not necessary if
replacing the furnace).
8. Press the [E] key.
If you are replacing the entire furnace,
proceed with Step 4a.
If you are cleaning or replacing the
combustion pipe, proceed with
Step 4b.

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Step Display Description

4a Only if replacing the furnace: ! CAUTION

Contact with hot parts of the
COMBUSTION PIPE combustion furnace may cause
injury!
‣ Use heat-resistant gloves.

XXX
1. Detach the outflow hose on the
mounting plate or on the salt
TEMPERATURE = °C
trap, if a heated salt trap
(optional) is fitted.
2. Release the locking button on the
furnace and swivel the furnace
outwards.
MAINTENANCE COMPLETED?
3. Release the electrical plug-in
connections between the
[E] TO CONFIRM analyzer and the furnace.
4. Remove the furnace.
5. Press the [E] key.
Continue with Step 7.

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Step Display Description

4b Only if cleaning or replacing the combustion pipe: ! CAUTION

Contact with hot parts of the
COMBUSTION PIPE combustion furnace may cause
injury!
‣ Use heat-resistant gloves.

XXX
1. If a heated salt trap is not fitted,
release the hose connection
TEMPERATURE = °C
between the furnace outlet
(item 5) and the mounting plate.
2. Remove the knurled head screw
(item 6). Remove the furnace
outlet and the O-ring from the
MAINTENANCE COMPLETED?
combustion pipe.
3. Release the red screw plug
[E] TO CONFIRM (item 2) and remove the dosing
head (item 1).
4. Remove the safety guard.
5. Release the thread adapter nut on
the furnace entry (item 4) and
remove the furnace cover.
6. Remove the O-ring and support
ring.
7. Unlock the furnace and pull it out.
8. Using the auxiliary tool, pull the
combustion pipe insert
approx. 10 mm (0.4") out of the
combustion pipe. Then remove
the combustion pipe insert using
the crucible tongs, and take out
the filling.
Put the waste in a container
for inorganic materials.
Dispose of the used catalyst
as hazardous waste in
accordance with local laws
and safety regulations. Do
not pour it down the drain
or into a garbage can!
9. Lift the combustion pipe under
the furnace and using the crucible
tongs remove it from the furnace
from the top.
10. If necessary, clean the
combustion pipe using a brush.

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Step Display Description

5 Reassembling the combustion unit

1. Insert the combustion pipe into the tube furnace.

2. Place the combustion pipe insert with filler (approx. 25 g high-temperature catalyst) into the
combustion pipe.
3. Check and clean the support ring and sealing ring for the furnace cover and insert the sealing
ring and the support ring.
4. Fit the cleaned furnace cover and the thread adapter nut on the furnace entry and tighten the
thread adapter nut.
5. Mount the dosing head with the O-ring, and tighten the red screw plug.
6. If you are not using the optional heated salt trap, fit the furnace outlet with a glass fiber fabric
as the salt trap. Roll two fabrics together loosely and put the fabrics loosely into the furnace
outlet. Approx. 10 mm (0.4") must remain free at the top end to catch the salt.
7. If you are using the optional heated salt trap, leave the furnace outlet empty.
8. Insert the cleaned furnace outlet and a clean O-ring into the combustion pipe and tighten the
knurled head screw hand-tight.
9. If you are not using the optional heated salt trap, connect the hose from the furnace outlet to
the bulkhead gland on the mounting plate.

6 If you are using the optional heatable salt trap:

1. Turn the salt trap gently to push it onto the furnace outlet nozzle.
2. Make sure that the seal seals the glass nozzle with a slight suction effect. You can adjust the
seal with the clamp screw. The seal should not be too tight however.
3. Push the salt trap under the furnace.
4. Fold down the retaining bar and rest the filter on the bar.
5. Plug in the electrical contact and lock it.
6. Fit the hose on the heatable salt trap and screw it down.

Press the [E] key.

7 1. Once you have replaced the entire

furnace, connect the hose to the
mounting plate or to the heated
salt trap (optional). Connect the
electrical plug-in connections
between the furnace and the
analyzer.
2. Move the furnace into position
and secure it.
3. Press the [E] key.

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Step Display Description

8 1. Install the hose at the injection

unit.
2. Check that the hose is correctly
inserted in the magnetic valve 8.
3. Press the [E] key.

9 The carrier gas valve MV7 (relay #7)

is opened as soon as 85% of the set
temperature is reached.
The system flushes permanently with
carrier gas.

Sample conditioning takes place (strip

chamber) after the furnace is being
heated.
Operation starts automatically.

Now carry out a leakage test (see

"Leakage test" section).

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8.9.7 Leakage test

This section describes how the gas circuit is checked for leaks.
Check the leak-tightness of the gas circuit after each modification to the furnace.
You require the following parts:
• Drain plug from the accessories supplied

1
2

a0012531

Fig. 58: Left-hand side of the housing

1 Gas outlet
2 Switch for membrane compressor

Step Display Description

1 S E R V I C E

PUMPS

CALIBRATION

CLEANING SCREEN FLUSH

POWER-FLUSH
FILTERS BYPASS-SCREEN
STRIPPER+SEPARATION
OPEN GAS CICUIT
COMBUSTION PIPE
LEAKAGE TEST

2 LEAKAGE TEST 1. Switch off the membrane

compressor (item 2).
2. Seal the gas outlet with a plug
(left-hand side panel, item.1).
SWITCH MEMBRANE COMPRESSOR OFF 3. Press the [E] key.
SHUT GAS OUTLET

[E] TO CONFIRM

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Step Display Description

3 Press the [->] key.

The carrier gas valve is opened and
pressure is applied to the gas circuit.
The pressure is shown on the display.

The carrier gas valve is closed

automatically:
• If the pressure has exceeded 100
mbar or
• Once 7 seconds have elapsed.
If the pressure does not reach
100 mbar, this indicates a
sizable leak.

4 LEAKAGE TEST The pressure loss rate is displayed

(mbar/min) after 30 s.
The pressure loss must be < 3 mbar/
min. Values are typically between -
0.5 and -2.0 mbar/min.
CARRIER VALVE SHUT XXX mbar
If the loss in pressure is > 3 mbar/
min, divide the gas circuit into smaller
x.xxx mbar/min XX sec sections. Bridge the individual
components using a hose, and repeat
the leakage test until you have found
the leak. If there is no pressure loss in
a bridged component e.g. a
component of the furnace with the
[E] TO CONFIRM
salt trap, the leak is in the bridged
component.

Press the [E] key.

5 LEAKAGE TEST 1. Remove the plug from the gas

outlet (left-hand side panel).
2. Switch on the membrane
compressor.
OPEN GAS OUTLET 3. Press the [E] key.
SWITCH MEMBRANE COMPRESSOR ON
Operation starts.

[E] TO CONFIRM

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Possible points where a leak might be present:

• Furnace seals
• Acid filter seal at the glass
• Condensate drain
• Water block filter
To find the leak, the following tools in the "Maintenance tool kit" (see "Spare parts" section)
are available for the purpose of bridging components:
• Hose D 3/5 mm FPM
• Hose connector 1/8 - 1/8 PP
To seal the gas outlet on the furnace:
• Protection cap
• Reducing adapter 8/4 mm, straight
To seal the gas outlet on the housing:
• Plug M3 EPDM

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8.10 Filters

8.10.1 Replacing the acid filter

This section describes how the acid filter is replaced.
Replace the acid filter:
• If it is blocked or worn out. This is noticeable from the flow rate and pressure level of the
gas circuit.
• If zinc or copper become completely and obviously discolored.

a0012500

Fig. 59: Position of the acid filter

You require the following parts (part of the wear parts kit):
• Glass fiber fabric
• Zinc pellets
• Copper powder

1
5 5 5
2
3 6 6 6

4
8

a0012316

Fig. 60: Acid filter

1 Coupling 5 Glass fiber fabric

2 Retaining clip 6 Zinc
3 Filter glass body 7 Copper
4 GL coupling 8 Glass fiber fabric

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Step Display Description

2 REPLACE ACID FILTER ! CAUTION

Risk of injury due to aggressive
materials.
‣ Wear protective gloves!
1. Release the couplings (items 1
MAINTENANCE COMPLETED ? and 4).
2. Remove the acid filter (item 3)
from the retaining clips (item 2).
3. Remove the filling in the acid
filter.
4. Clean the glass if necessary.
[E] TO CONFIRM 5. Roll the fabric into a roll and push
it into the filter glass (item 8).
Do not press it in too hard.
Shorten the fabric if necessary.
6. Fill the glass up to the halfway
mark with copper and then with
zinc (see order of items 6 and 7).
Allow enough room for the
second piece of fabric.
7. Roll the fabric into a roll and use
it to close the filling in the acid
filter (item 5).
8. Clean the O-rings and seal the
acid filter. Make sure that the
fabric does not extend as far as
the plug to ensure the filter
housing is sealed properly (see
zoom detail of  å 60).
9. Fit the acid filter into the
retaining clips and connect the
filter.
10. Press the [E] key.

Operation starts (initially without a

measured value).

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8.10.2 Replacing the gas filter

This section describes how the gas filter is replaced.
Replace the gas filter if it is blocked.

a0012500

Fig. 61: Position of the gas filter

1
IN
2
3

OUT
a0012307

Fig. 62: Gas filter

1 Coupling
2 Gas filter
3 Coupling

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Step Display Description

2 REPLACE GAS FILTERS 1. Release the couplings (items 1

and 3).
2. Replace the gas filter (item 2).
Take the direction of flow into
account.
MAINTENANCE COMPLETED ? 3. First secure the filter in the
coupling (item 3) and then
connect the filter to the acid filter
with the coupling (item 1). Make
sure that the cone is properly
positioned on the filter.

[E] TO CONFIRM

4. Tighten the two couplings.

Operation starts (initially without a

measured value).

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8.10.3 Replacing the O2 filter

This section describes how the O2 filter is replaced.
The gas connection block with the O2 filter is mounted on the rear of the analyzer.
You require the following parts:
• Open-ended wrench
• Needle-nosed pliers

2 3

a0012321

Fig. 63: Gas connection block with O2 filter

1 Gas connection block
2 O2 filter
3 Coupling

Step Display Description

2 ! CAUTION
Risk of injury due to release of
pressure
‣ Wear protective goggles!
1. Close the valve for the carrier gas
supply.
2. Relieve the pressure on the
pressure line before opening the
hose connection to prevent injury
from the uncontrolled release of
pressure.
3. Press the [E] key.

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Step Display Description

3 REPLACE O2 FILTER 1. Release the coupling (item 3).

2. Check the O2 filter (item 2) for
possible signs of wear. Replace
the filter if necessary.
3. Screw the coupling into the gas
MAINTENANCE COMPLETED ? connection block.
4. Press the [E] key.

[E] TO CONFIRM

4 1. Reconnect the gas supply.

2. Open the gas supply valve.
3. Press the [E] key.

5 REPLACE O2 FILTER The analyzer display switches to

step 6 after 10 seconds.

PLEASE WAIT XX
6 The furnace heats up. Measuring
operation starts automatically as soon
as 90% of the set temperature is
reached and the CO2 value has
dropped below the threshold value.

During this time, sample conditioning

takes place (strip chamber) and
pH regulation is activated.

Measuring operation commences if

these two conditions are met.

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8.10.4 Replacing the heated salt trap

This section describes how to replace the heated salt trap (referred to as "heated filter" in the
menu).

a0012515

Fig. 64: Position of heated salt trap

You require the following parts:

• 4 mm Allen key
• Deionized water
• Heat-resistant gloves

5
6

a0012516 a0012517

Fig. 65: Heated salt trap when installed Fig. 66: Heated salt trap, open
1 Retaining bracket 3 Allen screws
2 Heated salt trap with insulation 4 Filter housing, top section
7 Clamp screw 5 Filter cartridge
6 O-ring

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To ensure that the furnace does not cool down too much during the cleaning process, it
is heated between the point the salt trap is removed and the salt trap is installed.
Extended measuring device downtime results if the furnace cools down too much, and
should therefore be avoided.

Step Display Description

2 ! CAUTION
Contact with hot parts of the
combustion furnace may cause
injury!
‣ Use heat-resistant gloves.
Carry out the following tasks quickly
to ensure the furnace does not cool
down too much:
1. Release the hose connections on
the dosing head.
2. Unlock the furnace and swivel it
outwards.
3. Release the electrical connection
to the salt trap.
4. Press the [E] key.

3 Confirm that you disconnected the

electrical connection to the salt trap.

The furnace is reheated and the

temperature displayed.

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Step Display Description

4 1. Release the hose at the outlet of

the heated salt trap.
2. Raise the salt trap (item 2)
slightly.
3. Fold back the retaining bracket
(item 1).
4. Remove the salt trap (item 2)
from below.
5. Remove the insulation.
6. Release the two screws (item 3)
and remove the top part of
the filter housing (item 4).
7. Clean the inside of filter cartridge
(item 5) and the filter housing
with deionized water.
8. Clean the O-ring (item 6) and fit
it back into the groove.
9. Screw the filter housing together
and insert it into the insulation.
10. Press the [E] key.

5 Carry out the following tasks quickly

to ensure the furnace does not cool
down too much:
1. Fit the salt trap on the glass
nozzle of the furnace.
2. Make sure that the seal seals the
glass nozzle with a slight suction
effect. You can adjust the seal
with the clamp screw (item 7).
The seal should not be too tight
however.
3. Push the salt trap under the
furnace.
4. Fold down the retaining bar and
rest the salt trap on the bar.
5. Reestablish the electrical
connection.
6. Press the [E] key.

6 The furnace is reheated and the

temperature displayed.
1. Connect the hose to the outlet of
the salt trap.
2. Swivel the furnace back and
ensure that the hose passes
comfortably through the rear
panel and is not buckled.
3. Lock the furnace.
4. Reestablish the hose connection
at the dosing head.
5. Press the [E] key.

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Step Display Description

7 The analyzer waits until the

temperature is 30 ° below the set
temperature.

8 Press the [E] key to start measuring

operation.

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8.10.5 Replacing the filter pads in the ventilators

This section describes how the filter pads in the ventilators are checked and replaced.

a0021275

Fig. 67: Position of filter pads

To replace the filter pads, you will require the following parts:
• Replacement filter pad AM 115P (2x)
• Replacement filter pad AM 335P (1x)
Proceed as follows:
1. Remove the safety guard (no tool necessary).
2. Check if the filter pads are soiled.
3. Replace the soiled filter pads.
4. Put the safety guard back in.
Ensure that the ventilation slits on the safety guard are pointing down.

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9 Repair
9.1 Spare parts
pH electrode for strip chamber
Order No.: CPS71-1TB2GSA
Wear parts kit for one year
Order No.: 71095156 for versions with standard furnaces

Name Quantity

Flange seal D 53.9 x 63 x 3.1 mm 1

O-ring D 36.09 x 3.53 mm FKM 1

O-ring D 1.5 x 1.5 mm FPM 2

O-ring D 8 x 2 mm FPM 1

Capillary 1.6 x 0.8 x 71 mm AL23 1

Catalyst 800 - 900 °C 75 g pack 1

Cone for coupling 1/8" 28 UNF ETFE 2

Coupling with nozzle 1/4"-28 D1.55 ETFE 4

Coupling with nozzle 1/4"-28 D3.20 ETFE 2

Fiberglass precut part, acid filter 24 x 230 mm 8

Copper, powder 50g pack 2

Zinc, granules, 60g pack 2

O-ring D 33 x 3 mm EPDM 1

O-ring D 12 x 1.5 mm EPDM 1

Filter cartridge 12 x 1 mm frit, porosity 4 1

O-ring D 35 x 3 mm EPDM 1

Capillary 1.6 x 0.8 x 45 mm AL23 1

Membrane for solenoid valve 330 A EPDM 2

Hose cassette, Ismatec CA71 2

Hose 2.79 / 4.59 PharMed violet/white 4

Hose 0.76 / 2.36 PharMed black/black 12

Glass balls D 2 mm 10-piece pack 1

Replacement filter pad AM 115P, air outlet 2

Replacement filter pad AM 335P, air outlet 1

Replacement membrane filter (gas filter) 1

Dust mask FFP3 3

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Name Quantity

Plug M3 EPDM 1

Protection cap 1

Order No.: 71095149 for versions with heated salt trap

Contains all the parts of 71095156 and also:

Name Quantity

O-ring D 64 x 2.5 mm FPM 1

Seal, glass tube heating filter 1

Filter sleeve, 25 x 64 20μ PTFE 2

Coupling D 4/6 G1/8 PP 1

Maintenance tool kit

Order No.: 71102317

Name Quantity

Plug M3 EPDM 1

Hose D 3/5 mm FPM 0.6

Protection cap 1

Hose connector 1/8 - 1/8 PP 2

Dosing needle D 0.84 mm, green 1

Injector 20 ml 1

Hose iD 1/2 mm Tygon 400 mm 1

Auxiliary tool for the salt trap 1

Crucible tongs 200 mm in length 1

Heat-resistant gloves (1 pair) 1

Gloves, resistant to acids and bases, large (1 pair) 1

Installation tool for seal set 1

Reducing adapter 8/4 mm, straight 1

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Wear parts kit for strip and separation chamber

Order No.: 71101606

Name Quantity

O-ring D 1.5 x 1.5 mm FPM 1

O-ring D 8 x 2.5 mm FPM 1

O-ring D 33 x 3 mm EPDM 1

O-ring D 12 x 1.5 mm EPDM 1

Filter cartridge 12 x 1 mm frit, porosity 4 1

O-ring D 35 x 3 mm EPDM 1

Capillary 1.6 x 0.8 x 45 mm AL23 2

Glass balls D 2 mm 10-piece pack 1

Stirrer support, complete, for 100 μ particles 1

Wear parts kit for acid filter

Order No.: 71101607

Name Quantity

Zinc, granules, 60g pack 3

Copper, powder 50g pack 3

Fiberglass precut part, acid filter 24 x 230 mm 2

Wear parts kit for predilution pump

Order No.: 71101608

Name Quantity

Coupling, short thread 1/8" - 28 UNF ETFE 1

Cone for coupling 1/8" - 28 UNF ETFE 1

Seal set D10 1

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9.2 Decommissioning
! CAUTION
There is a risk of infection if you come into contact with wastewater.
‣ Wear protective gloves, protective goggles and a protective laboratory coat!
Proceed as follows to take the analyzer out of service:
1. Switch off the wastewater pump.
2. If sample preparation is present: Trigger a screen flush (CLEANING - SCREEN FLUSH).
Allow the bypass to drain.
3. Optional dilution water pump P5: Flush the pump with 5 % acid followed by DI water.
Use the TEST menu to control pump P5. You can pump the acid and the DI water directly
out of the feeder tank.
4. Flush the hoses.
Set valve 1 to Manual sample and place a container with deionized water under the
valve.
TEST - TEST OF OUTPUTS - PUMPS
Enter 400% for pump P1 and pump P4 (optional) and let the pumps pump for some
time.
Remove the acid hose of pump P3 from the acid canister and insert it into a container
with deionized water. Also let this pump run at 400 % for some time.
5. Clean the vessels
Trigger an automatic flush of the strip chamber (CLEANING - POWER FLUSH).
Afterwards, perform manual cleaning of the strip and separation chamber (CLEANING
- STRIPPER & SEPARATION). The pH sensor must be stored wet. Fill the protection cap
with 3-mole KCl solution and fit the protection cap onto the sensor.
6. Empty the hoses
Open the hose cassettes of pumps P1, P2, P3 and (if optional dilution takes place) P4.
Let the rinse water run out of the hoses.
Remove the canister with the standard.
TEST - TEST OF OUTPUTS - SWITCH OUTPUTS
Switch the switch outputs SA1 and SA4 to "ON". Wait until the pipes for standard 1 and
2 are empty.
Switch the switch outputs "OFF" again.
Remove the feeder tank.
7. Switch off the main switch on the analyzer.
8. Empty the combustion pipe insert
Empty the combustion pipe insert (see "Maintenance - Combustion pipe" section).
Do not dispatch the analyzer with the combustion pipe insert still inserted (risk of
breakage).
Empty the glass insert.
Assemble the combustion unit.
9. Remove the exhaust (if present).
10. Close off the carrier gas supply.
Relieve the pressure on the pressure line before opening the hose connection to prevent
injury from the uncontrolled release of pressure.
Unscrew the hose for the carrier gas supply on the left side panel.
Detach the hose on the pressure-reducing valve of the carrier gas cylinder or gas
preparation system.

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9.3 Return
The product must be returned if repairs or a factory calibration are required, or if the wrong
product was ordered or delivered. Legal specifications require Endress+Hauser, as an
ISO-certified company, to follow certain procedures when handling products that are in
contact with the medium.
To ensure that your device is returned swiftly, safely and in an appropriate manner,
please read the procedures and conditions on the Endress+Hauser website at
www.services.endress.com/return-material

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

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10 Accessories
Reagents
‣ CAY450-V10AAE, 1000 ml stripping reagent for CA72TOC
‣ CAY451-V10C01AAE, 1000 ml parent solution 5,000 mg/l TOC
‣ CAY451-V10C10AAE, 1000 ml parent solution 100,000 mg/l TOC
Technical buffer solutions, accuracy 0.02 pH, traceable to NIST/DIN
‣ pH 4.00; 20 x 18 ml (0.68 fl. oz); Order No. CPY20-C01A1
‣ pH 7.00; 20 x 18 ml (0.68 fl. oz); Order No. CPY20-E01A1
Furnace conditioning station
‣ 230 V AC 50/60 Hz order number: 71103492
‣ 115 V AC 50/60 Hz order number: 71103493
Standard furnace
‣ To be used as a second furnace or as a substitute
‣ Cannot be used with heated salt trap
‣ Order number: 71091188
Furnace for heated salt trap
‣ To be used as a second furnace or as a substitute
‣ Order number: 71103888
Kit CA72TOC heated salt trap
‣ As replacement for maintenance (decreases the maintenance time) or as a replacement
‣ Order number: 71101532

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11 Technical data

11.1 Input

Measured variable TOC (TC possible without stripping unit)

Measuring range Version Measuring range

A 0.25 to 600 mg TOC/l

B 1 to 2400 mg TOC/l

C 2.5 to 6000 mg TOC/l

D 5 to 12000 mg TOC/l

With optional predilution, the measuring range can be expanded by a factor of 20.

Signal inputs 8 signal inputs 24 V DC, active, load max. 500 

Input #1 Service, trigger calibration

Input #2 Service, trigger adjustment

Input #3 Service, trigger screen flush

Input #4 Service, trigger power flush

Input #5
Input #6

Input #7 Trigger standby

Input #8 Trigger channel switchover (optional)

11.2 Output

Output signal Measuring channel 1: 0/4 to 20 mA, galvanically isolated

Measuring channel 2 (for two-channel version): 0/4 to 20 mA, galvanically isolated
Load: max. 500 

Data interface RS 232 C, proprietary, for data output and remote operation (optional)
Alarms 4 outputs: Limit value alarm, fault message, standby message and operating check,
potential-free, normally closed (max. 0.25 A / 50 V)

11.3 Power supply

Supply voltage 115/230 V AC, 50/60 Hz, 800 VA

Fuses Assembly Fuses

Power distribution 2.5 A, slow-blow, design: fine-wire fuse

6.3 x 32

Relay 4 A per relay, slow-blow, design: TR5

Power unit 2 A, slow-blow, design: fine-wire fuse 5 x 20

TOCII CA72TOC is suitable for connection to industrial power supply systems in accordance with
EN 61326-1, Class A.

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11.4 Performance characteristics

In accordance with ISO 15839
The performance characteristics have been determined in accordance with ISO 15839, Annex B. 300 μl sample
were metered into the TOCII (CA72TOC-B1A0B1) per measurement. This resulted in a measuring range from
4 to 800 mg/l. The following data refer to this device.
Slight deviations should be factored in if applying the performance characteristics to other measuring ranges.
LOD (limit of detection) 0.75 % of end of measuring
range
LOQ (limit of quantitation) 2.5 % of end of measuring
range
Short-term drift 0.5 %/day
Repeatability precision at 20 % of the measuring range 0.4 %
Resolution limit at 20 % of the measuring range (LDC) 1.1 %
Systematic measured value deviation at 20 % of the measuring range (BIAS) 0.4 %
Repeatability precision at 80 % of the measuring range 1.6 %
Resolution limit at 80 % of the measuring range (LDC) 4.6 %
Systematic measured value deviation at 80 % of the measuring range (BIAS) 2.4 %

11.5 Environment
Ambient temperature 5 to 35 °C (41 to 95 °F)
range
Humidity 20 to 80 %, non-condensing
Degree of protection IP 54

11.6 Process
Sample temperature 4 to 40 °C (39 to 104 °F)
Sample flow rate 20 ml/min (0.32 US gal/hr)
Sample feeder volume 90 ml (3 fl.oz)
PA-2, PA-3 and PA-9 are available for selection as sample preparations.
Sample consistency Aqueous
Flammable substances should not occur in combustible concentrations - sample
dilution is then necessary.
Sample supply Non-pressurized infeed to the analyzer from sample preparation.

11.7 Mechanical construction

Weight Approx. 75 kg (165 lbs)
Materials Housing Aluminum, powder-coated (RAL7035)
Window Glass, conductive coating
Valve seals EPDM, FPM, FFKM
Pump hoses Ismapren
Pumps and pump seals PTFE, FFKM
Reagent and sample hoses PTFE, PE
Exhaust gas and ventilation hoses PTFE, PE
Outflow hoses PTFE

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Index
A G
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Gas flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Adjusting pump P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 H
Adjusting the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Hose replacement
Adjusting the pH sensor . . . . . . . . . . . . . . . . . . . . . . . . . 106 P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
ALARM LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ALARM RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
I
B Incoming acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 20
BASIC DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bypass screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
K
C Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Calibrating the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 101
Changing the hose L
P1 and P4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Check LISTS
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ALARM RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 COMPLETE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Post-installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 MAINTENANCE RECORD. . . . . . . . . . . . . . . . . . . . . . . 46
Chemicals MIN MAX AVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 RECORD ALL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Citric acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 110
M
Combustion pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Adjusting the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 98
COMPLETE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Adjusting the pH sensor . . . . . . . . . . . . . . . . . . . . . . 106
Compressed air and water supply . . . . . . . . . . . . . . . . . . 11 Bypass screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Connection Calibrating the analyzer . . . . . . . . . . . . . . . . . . . . . . 101
Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Combustion pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Empty volume dosing . . . . . . . . . . . . . . . . . . . . . . . . 103
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
D Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Open gas circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Power flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Device designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacing the acid filter . . . . . . . . . . . . . . . . . . . . . . 132
Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . 61 Replacing the filter pads. . . . . . . . . . . . . . . . . . . . . . 142
Dilution water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Replacing the gas filter . . . . . . . . . . . . . . . . . . . . . . . 134
Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Replacing the heated filter . . . . . . . . . . . . . . . . . . . . 138
Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Replacing the O2 filter . . . . . . . . . . . . . . . . . . . . . . . 136
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Screen flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Dosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Service software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Strip and separation chamber . . . . . . . . . . . . . . . . . 116
E Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Electrical technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 MAINTENANCE RECORD. . . . . . . . . . . . . . . . . . . . . . . . . . 46
Empty volume dosing . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Measuring range adjustment . . . . . . . . . . . . . . . . . . . . . . 56
Error messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 MEASURING SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Media
F Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Filter pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Methods of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 MIN MAX AVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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N T
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
TEST
O INPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Open gas circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Two-channel
Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 External changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Time-controlled changeover . . . . . . . . . . . . . . . . . . . . 54
P
Pivoting frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 U
Post-connection check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Updating the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Potassium hydrogen phthalate . . . . . . . . . . . . . . . . . . . . . 17
Power flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 W
Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Programming mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Workplace safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

R
RANGE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Reagent quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Recording mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Replacing the acid filter . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Replacing the gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Replacing the heated filter . . . . . . . . . . . . . . . . . . . . . . . 138
Replacing the O2 filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Requirements for personnel . . . . . . . . . . . . . . . . . . . . . . . . 5
Return. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

S
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Salt load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Screen flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Set brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SET CLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Set contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SETTING
ALARM LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
BASIC DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
MEASURING SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
RANGE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SET BRIGHTN./CONTR. . . . . . . . . . . . . . . . . . . . . . . . . 42
SET CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Signal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Spot view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Standard
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Standard concentrations . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Standby mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Strip and separation chamber . . . . . . . . . . . . . . . . . . . . . 116
Stripping reagent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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