Operation Manual 5000TOCi Sensor - Mettler Toledo

Total Organic CarbonMeasurement System

Operation Manual 5000TOCi Sensor

5000TOCi Sensor 58 130 246

© 09 / 13 Mettler-Toledo Thornton 5000TOCi SensorPrinted in USA

5000TOCi Sensor


Operation Manual 5000TOCi Sensor

5000TOCi Sensor


5000TOCi Sensor 5

© 09/13 Mettler-Toledo Thornton 5000TOCi SensorPrinted in USA

Contents1 Introduction ______________________________________________________________________________________________ 72 Safety instructions_________________________________________________________________________________________ 8

2.1 Definitionofequipmentanddocumentationsymbolsanddesignations ___________________________________________ 82.2 Correctdisposaloftheunit _____________________________________________________________________________ 9

3 5000TOCi Unit overview ___________________________________________________________________________________ 103.1 HighPressureApplications _____________________________________________________________________________ 113.2 PotentialCondensationApplications _____________________________________________________________________ 113.3 HighPressureApplications _____________________________________________________________________________ 11

4 5000TOCi Installation Instructions___________________________________________________________________________ 124.1 Unpackingandinspectionofthe5000TOCi ________________________________________________________________ 124.2 Installationofthe5000TOCi ____________________________________________________________________________ 124.3 SampleTubingConnections ____________________________________________________________________________ 134.4 SampleConditioningCoil ______________________________________________________________________________ 144.5 ACPowerConnection _________________________________________________________________________________ 144.6 SensorConnection __________________________________________________________________________________ 15

5 5000TOCi Sensor Operation _______________________________________________________________________________ 165.1 InitialStartup _______________________________________________________________________________________ 165.2 InitiateSampleFlow __________________________________________________________________________________ 165.3 5000TOCiQuickSetup ________________________________________________________________________________ 165.4 NormalOperation ____________________________________________________________________________________ 165.5 Calibration _________________________________________________________________________________________ 16

5.5.1. TOCCalibrationMethods ________________________________________________________________________ 175.5.2. EnterCalibrationMode _________________________________________________________________________ 17

5.6 SystemSuitabilityTesting ______________________________________________________________________________ 18

6 5000TOCiandM800Configuration __________________________________________________________________________ 196.1 ChannelSetup ______________________________________________________________________________________ 196.2 ParameterSettings __________________________________________________________________________________ 206.3 ISMSetup _________________________________________________________________________________________ 216.4 ISM/SensorAlarm __________________________________________________________________________________ 226.5 Reset _____________________________________________________________________________________________ 236.6 ISMDiagnostics ____________________________________________________________________________________ 236.7 CalibrationData ____________________________________________________________________________________ 256.8 SSTInformation _____________________________________________________________________________________ 256.9 TOCMaintenance30 __________________________________________________________________________________ 25

7 5000TOCi Sensor Service Requirements _____________________________________________________________________ 277.1 UVLampReplacement ________________________________________________________________________________ 277.2 FrontPanelCleaning _________________________________________________________________________________ 287.3 TechnicalSupport ____________________________________________________________________________________ 287.4 HighCapacityInletFilterReplacement ____________________________________________________________________ 297.5 DrainingandShippingInstructions ______________________________________________________________________ 29

8 Troubleshooting the 5000TOCi Sensor _______________________________________________________________________ 308.1. BasicTroubleshooting ________________________________________________________________________________ 308.2. FaultandErrorMessages ______________________________________________________________________________ 30

9 Accessories and Spare Parts _______________________________________________________________________________ 339.1 M800Transmitter ____________________________________________________________________________________ 339.2. 5000TOCiSensorAccessoriesandSpareParts _____________________________________________________________ 339.3. 5000TOCiSensorConsumableItems ____________________________________________________________________ 34

10 5000TOCi Sensor Default Settings___________________________________________________________________________ 3511 5000TOCiSpecifications __________________________________________________________________________________ 3612 Warranty _______________________________________________________________________________________________ 3713 Certificate ______________________________________________________________________________________________ 38

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1 IntroductionStatementofintendeduse–The5000TOCisensorisaTotalOrganicCarbonsensorwithISMcapabilities,designedtomeasuretheconcentrationoforganicsubstancesinpureandultrapure waterapplications.The5000TOCiisacontinuous-flowing,continuous-measurementinstrumentallowingdetectionofanyTOCchangeregardlessoftheduration.Thecontinuousdesignalsoallowsrapiddetection,withchangesbeingrecognized60secondsfromthetimethesampleentersthe sensor.

TheM800Transmitter,isamultiparameter,multi-channelinstrumentwithalarge,colortouch-screendisplaywhichconveysmeasurementandsetupinformationforthe5000TOCisensor.TheM800iscapableofcontrollingandmonitoringtheoperationofupto45000TOCisensors.

Whenusedincombination,the5000TOCisensorandM800transmitterformaTOCmeasurementsystemwhichprovidesthedesignflexibilityforfullintegrationintowatersystems.Theseparatecomponentsallowforclosepositioningofthesensortothesamplepointforfastestresponse,whileallowingintegrationofthetransmitterintothelocalcontrolsystem.

Thismanualappliestothe5000TOCisensorfamily,listedbelow.FormoreinformtiononthefeaturesoftheM800Transmitter,pleaserefertotheM800OperatingManual.

5000TOCi Sensor FamilyDesignation Order no.5000TOCi Sensor, 110VAC, 50/60 Hz 58 036 0315000TOCi Sensor, 220VAC, 50/60 Hz 58 036 0325000TOCi Sensor, Low ppb calibration, 110VAC, 50/60 Hz 58 036 0335000TOCi Sensor, Low ppb calibration, 220VAC, 50/60 Hz 58 036 034

Thescreenimagesinthismanualareintendedforgeneralexplanation,andcandifferfromtherealdisplayinyourtransmitter.

Thisdescriptioncorrespondstothefirmwarerelease,version1.1oftheM800transmitter.Changesaretakingplaceconstantly,withoutpriornotification.

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2 Safety instructionsThismanualincludessafetyinformationwiththefollowingdesignationsandformats.

2.1 Definitionofequipmentanddocumentationsymbolsanddesignations

WARNING:RISKOFELECTRICALSHOCK.

a CAUTION:possibleinstrumentdamageormalfunction.

h NOTE:Importantoperatinginformation.

~ On the instrument indicates:Thereisalternatingcurrentpresent.

Thefollowingisalistofgeneralsafetyinstructionsandwarnings.Failuretoadheretotheseinstructionscanresultindamagetotheequipmentand/orpersonalinjurytotheoperator.

– The5000TOCiSensorshouldbeinstalledandoperatedonlybypersonnelfamiliarwiththesensorandwhoarequalifiedforsuchwork.

– The5000TOCiSensormustonlybeoperatedunderthespecifiedoperatingconditions.– Repairofthe5000TOCiSensormustbeperformedbyauthorized,trainedpersonnelonly.– Ifthisequipmentisusedinamannernotspecifiedbythemanufacturer,theprotectionprovidedby

theequipmentagainsthazardsmaybeimpaired.– Useonlyfactorydocumentedcomponentsforrepair.Mettler-Toledoacceptsnoresponsibilityfor

damagecausedbyunauthorizedmodificationstothesensor.– Followallwarnings,cautions,andinstructionsindicatedonandsuppliedwiththisproduct.– Protectivecoversmustbeinplaceunlessqualifiedpersonnelareperformingmaintenance.– Installequipmentasspecifiedinthisinstructionmanual.Followappropriatelocalandnational

codes.– Protectivecoversmustbeinplaceatalltimesduringnormaloperation.– Priortoshippingsensorbacktothefactoryforrepairorre-calibration,waterMUSTbedrained

fromsensortoavoiddamageduetofreezing.

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WARNINGS:– Installationofcableconnectionsandservicingofthisproductrequireaccesstoshockhazard

voltagelevels.Switchorcircuitbreakershallbeincloseproximitytotheequipmentandwithin easyreachoftheOPERATOR;itshallbemarkedasthedisconnectingdevicefortheequipment.

– Mainpowermustemployaswitchorcircuitbreakerasthedisconnectingdevicefortheequipment.ElectricalinstallationmustbeinaccordancewiththeNationalElectricalCodeand/oranyotherapplicablenationalorlocalcodes.Safetyandperformancerequirethatthissensorbeconnectedandproperlygroundedthroughathree-wirepowersource.

– Ozonegas(O3)isgeneratedinsidethe5000TOCiSensorenclosureduringnormaloperation.Thesmellofozonemaybeapparentwhenopeningthefrontcoveroftheenclosureandcautionshouldbetakenwhenopening.Prolongedexposuretoozonegasishazardousandmaycausehealthproblems.

h NOTE! PROCESS UPSETS:Becauseprocessandsafetyconditionsmaydependonconsistentoperationofthissensor,provideappropriatemeanstomaintainoperationduringsensormaintenance,replacementorsensororinstrumentcalibration.

2.2 Correct disposal of the unit

Whenthesensorisfinallyremovedfromservice,observealllocalenvironmentalregulationsforproperdisposal.PleasenotetheUVlampsuppliedwiththe5000TOCicontainsmercury.

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3 5000TOCi Sensor OverviewThe5000TOCiSensorisaTotalOrganicCarbonsensordesignedforusewiththeM800transmitter.TheM800willautomaticallyidentifythe5000TOCiSensorwhenitisconnected,andallfactorycalibrationdataisautomaticallyreadandusedforoperationandindication.

The5000TOCiSensorandM800transmitterareconfiguredwithfactorydefaultsettingstominimizemeasurementsetuptime.Thesedefaultsettingsallowforsensoroperationwithminimalconfigurationatsystemstartup.The5000TOCiSensorhasmorefeaturesthanothersensorsandmayrequireadditionalconfigurationdependantupontheoperationalsetup.Oncetheseparametersareset,theTOCsensorwillfunctionautomatically,andwillrequireuserinterfaceonlyforperiodicserviceandmaintenance.Measurementsavailablefromthe5000TOCiSensorincludeTOC,Conductivity/Resistivity(compensatedanduncompensated),Temperature,AverageTOCandPeakTOC.

The5000TOCiSensorisdesignedwithfourlocalLEDindicatorsandaUVLampcontrolkeyonthefrontpanel,asshownintheillustrationbelow.TheLEDsaredesignedtoprovidelocalindicationofsensorstatus.TheoperationoftheLEDsissynchronizedwiththeM800faultanderrorstatusmessagesandindications.

Function Color OperationFault Red FlashesduringFaultcondition,sensoroperationstoppedError Amber IlluminatesduringErrorcondition,sensorremainsoperational

SensorStatus GreenIlluminateswheneverACPowerisonandthe5000TOCiisconnectedtoanoperatingM800

UVLampOn Green IlluminateswhenevertheUVLampison

TheUVLampcontrolkeyisdesignedtoprovidealocalOn/OffcontrolfortheUVlamptoallowfor quicklampreplacementandtoassisttheoperatorduringtroubleshooting,ifnecessary.

NOTE:OncetheUVLampKeyispressedtoturntheUVLampoff,theUVLampcannotbeturnedonfromtheM800,itcanonlybeturnedonbypressingthesensorkeyagain.Thisfunctionisintendedtoavoidaccidentalactivationduringmaintenance.

Thefrontcoverofthesensorishingedontheleftside.Locatedatthetopandbottomrightcornersofthesensorenclosurearetwotriangle-shapeddoorfasteners.TheinstallationkitprovidedwiththeSensorincludesthespecialtoolneededtoloosenthesefastenersandopenthefrontdoortotheenclosure.Periodicaccesswillberequiredtoperformroutineserviceandmaintenance.Additional

h

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frontcovertoolsareavailablefromMettler-ToledoThornton,Inc.Seethesparepartslistinginthismanualforpartnumbersanddescriptions.

3.1 High Pressure Applications

Forinstallationswithprocesspressureabove85psig(5.9bar),theHighPressureRegulator(p/n58091552)isrequired.RefertoSampleTubingConnectionsforadditionalinformation.DetailedinstallationinstructionsaresuppliedwiththeHighPressureRegulator.

3.2 Potential Condensation Applications

Certainambientandprocesstemperaturesmaycausecondensationtooccurinsidethe5000TOCiSensor.TheMettler-ToledoThorntonSampleConditioningCoilprovidedwiththesensorinstallationkitisdesignedtoreducecondensationconditionsbyallowingthesampletemperaturetopartiallyequalizewiththeambienttemperature.

3.3 High Temperature Applications

Forwatertemperaturesfrom70°Cto100°C(158°Fto212°F),theSampleConditioningCoil(p/n58071518)isrequired.Inhighpressureapplications,theHighPressureRegulator(p/n58091552)mustbeinstalledupstreamoftheSampleConditioningCoil.

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4 5000TOCi Installation Instructions

4.1 Unpacking and inspection of the 5000TOCi

Carefullyunpackthe5000TOCisensor.Theboxcontainsthefollowingitems:

• 5000TOCiSensor• 5000TOCiSensorInstructionManualCD• 5000TOCiStart-upBooklet(IncludedwithCD)• CertificateofCalibration• InstallationKitincludes: OneSampleInletTube-6foot(2m)lengthofPTFEtubing,0.125inch(3mm)O.D. OneSafetyDrainTube-5foot(1.5m)lengthoftubing,0.31inch(8mm)O.D. Onestainlesssteeloutlettube One-Plastic30ccSyringe One-Tool,TOCCover One-HighCapacityInletFilterAssembly One-Adapter,0.25inch(6mm)O.D.to0.125inch(3mm)O.D.TubingReducer One–SampleConditioningCoil

4.2 Installation of the 5000TOCi

5000TOCi Sensor Dimension Diagram

Shownabovearethecasedimensionsforthe5000TOCiSensor.Mountthe5000TOCiSensoras closetothesamplepointofyoursystemaspossible.Shortersampletubinglengthbetweenthesamplingpointandthe5000TOCiSensorwillprovideafasterresponsetime.Asshownabove,the5000TOCiSensorissuppliedwithwall-mountingtabsforwallorpanelmount.

The5000TOCiSensorcanbemountedtoapipeusingapipe-mountaccessory(SeeAccessoriessectioninthismanual).Suddenshockorexcessivevibrationcanresultinsensordamage.Whenpipe-mountingthissensor,besurethepipeissecurelyfastened.

The5000TOCiSensorcanalsobeplacedonabench-toportable.Inthistypeofinstallation,themountingtabsmustberemovedfromthebottomofthesensorenclosureinorderforthesensorto

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standonitsown.Thebottomsafetydrainfittingshouldalsoberemovedforbenchtopinstallation,leavingthesmallopeninginthebottomoftheenclosureopen.

Someoftheinternalcomponentsforthesensoraremadeoffragilematerials;thereforeprecautionsshouldbetakentoavoiddamageduetoimproperhandling.The5000TOCiSensorrequiresroutinemaintenance;thereforeitisbeneficialtomountthesensorinaneasilyaccessiblelocation.

4.3 Sample Tubing Connections

Theinstallationkitprovidedwiththesensorincludessampletubingconsistingofone5-foot(1.5m)lengthof0.31inch(8mm)O.D.safetydraintubing,onestainlesssteeloutletdraintube,andone6-foot(2m)lengthofPTFEsampleinlettubingisincludedforthesupply.A0.25inch(6mm)O.D.to0.125inch(3mm)O.D.tubingreducerisalsoincludedandcanbeusedwhereapplicable.

Thefollowingitemsarenecessarytoensuretheproperinstallationofthesensor:• Sampleisolationvalve(notprovidedwithsensor).• 0.125inchcompressiontubefittingforsamplepoint(commontubefitting adaptersareavailablefromThornton;seeaccessoriesfordetails).

NOTE:Thesampleisolationvalveisrequiredtoisolatethesensorwhennecessary.Properinstallationguidelinesshouldbefollowedwheninstallingthisvalvetoreducethepossibilityofairentrapmentorsedimentinthesampleline.

1 Removetheprotectivecoversfromthesampleconnectionsonthesensor.

2 AttachedtheopentubeendofthePTFEtubingtothesampleisolationvalve.Cutexcesstubingtominimizesampletubinglength.Besureallfittingsareproperlyfastenedtoavoidleaksandthepossibilityofairingress.

3 Flushthesampleinlettubingtoremoveanyparticlesthatmaybeinthelineorfittingsbeforeconnectingittothe5000TOCiSensor,orpriortoinitialsensorstartup.

4 ConnectthestainlesssteeldraintubetotheSampleOutletconnection.Thefittingisattachedtothetube;thereforethreadthefittingintotheSampleOutletconnectiononthesensor.Donotovertighten.

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5 LocatetheHighCapacityInletFilterAssemblyprovidedinthesensorinstallationkit.Themale-threadedendoftheassemblyisscrewedintothefemale-threadedsampleinletfitting.Securetheassemblywithawrenchtoensuretheconnectionistight.Donotovertighten.

6 Connectthe0.125inch(3mm)PTFEtubingtothehighcapacityinletfilterbysecuringthetubing

inthecompressionfittingontheassembly.Donotovertighten. 7 Runthesafetydraintubingtoanatmosphericdrainlocatedclosetothesensor.Seetheillustration

inthesensorinstallationsectionfordimensionaldetailofthedrainlocation.Takenoteofthe6”(15cm)to36”(90cm)drainrequirement.

NOTE:Thestainlesssteeldraintubemustbefedtoanearbystandpipeordrainsumptocreateanairgapandpreventsiphoning.Installationmustadheretothedimensionsshownintheinstallationdiagramforpropersensoroperation.

4.4 Sample Conditioning Coil

1 Removecompressionfittingfromfilterassembly.Asshown,insertportconnectorintocompressionfittingthatwasremovedfromfilter.Reconnectcompressionfittingtothefilterassemblyandtightentocrimp.Donotovertighten.

2 ConnectFittingA(1/8”-1/8")ofSampleConditioningCoiltotheportconnectorandtightentocrimp.Donotovertighten.

3 AttachFittingB(1/8"X1/4”NPT)ofSampleConditioningCoiltoanappropriateconnectionontheprocesspipeorsamplesupplyline..

4 Ensurethatexcessiveforceisnotappliedtotheinletfittings.Ifnecessary,supporttheSampleConditioingCoilinanappropriatemanner.

NOTE:TheSampleConditioningCoilcanbestretchedtoextendthelengthupto3m(10’)maximum.

4.5 AC Power Connection

Asshownintheleftsideviewprovidedintheinstallationdiagram,thereisabulkheadcableglandlocatedontheleft-handsideofthesensorenclosurelabeled‘ACPOWER’toallowforthepassageoftheACpowercable(notprovidedwithsensor).IftheinstallationrequiresuseofhardconduitforACpower,thisfittingmayberemovedandtheholecanbeusedtoterminateaconduitfitting.

NOTE:Forconduitinstallation,useawatertightfittingandhubthatcomplywiththerequirementsofUL514B.Connecttheconduithubtotheconduitbeforeattachingthefittingtotheanalyzer(UL508-263.16).Theopeningacceptsa3/8”(9mm)NPTconduitfittingwithnut.

h

h

h

PortConnector

High CapacityFilter

Fitting A Fitting B

7.5"REF.

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TheterminalconnectionsforACpowerarelocatedontheprintedcircuitboardmountedtothefrontcoverofthesensor,asshownintheillustrationprovidedbelow.KeepACpowerseparatedfromallotherinternalwiring.UsethefastenersprovidedaspartoftheACterminaltosecurethepowerwires.Ensurethereisadequatecablelengthtoavoidputtingmechanicalstressonthewiringwhenthefrontdoorisfullyopened.ThediagrambelowshowstheterminalconnectionsforACpower.Besurethelinefuseisproperlyinstalledwhenmakingelectricalconnections.AsparefusekitisavailablefromThornton.Seethesparespartslistattheendofthismanualformoredetails.

4.6 Sensor Connection

Alsolocatedontheleft-handsideofthesensorenclosureistheconnectionfortheM800Transmitter,labeled‘TransmitterConnection’.TheM800patchcableslistedintheaccessorysectionattachdirectlytothisconnector.Tosecurethepatchcable,alignthekeysofthetwoconnectorsandthreadthecablematingconnectoruntilfingertight.Refertothetablebelowfordetailsonconnectingthe patchcabletotheM800Transmitter.

OncethetransmitterandACpowerconnectionsaresecured,andACpowerisappliedtothe5000TOCi,thesampleisolationvalvecanbeopenedandthesensorflushedwithsamplewater.

TB2 and TB4 – Terminal Assignment for 5000TOCiTB2 TB4 5000TOCi

Term. Function Function Sensor wire 1 DI2+ DI6+ – 2 DI2– DI6– – 3 1-Wire_Ch1 1-Wire_Ch3 – 4 GND5V_Ch1 GND5V_Ch3 – 5 RS485B_Ch1 RS485B_Ch3 black 6 RS485A_Ch1 RS485A_Ch3 red 7 GND5V_Ch1 GND5V_Ch3 white 8 5V_Ch1 5V_Ch3 blue 9 24V_Ch2 24V_Ch4 –10 GND24V_Ch2 GND24V_Ch4 –11 1-Wire_Ch2 1-Wire_Ch4 –12 GND5V_Ch2 GND5V_Ch4 –13 RS485B_Ch2 RS485B_Ch4 black14 RS485A_Ch2 RS485A_Ch4 red15 GND5V_Ch2 GND5V_Ch4 white16 5V_Ch2 5V_Ch4 blue

LINE FUSE

EARTH GROUNDNEUTRALLINE

ACLINEIN

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5 5000TOCi Sensor Operation

5.1 Initial Startup

Initialstart-upreferstotheconditionwherea5000TOCiSensorisinstalledandoperatedforthefirsttime.Factorydefaultsettingsfora5000TOCiSensoraredesignedtominimizesetuptimeforthissensorandallowthesensortomeasureautomatically.

5.2 Initiate Sample Flow

The5000TOCiSensorisdesignedtooperateoptimallyataflowrateof20mL/min.Theflowratethroughthesensoriscontrolledbyasolonoid-operatedautomaticflowcontrolvalvewhichisdesignedtocompensateforsupplypressurevariations.

Toestablishsampleflow,ensurethatthe5000TOCiisconnectedtoanM800Transmitter,andthatACpowerissuppliedtothe5000TOCiandM800.Slowlyopenthesamplelineisolationvalve.Oncesampleflowisestablished,the5000TOCisensorwillautomaticallyestablisha20ml/minflowrate.Allow3-5minutesforthesensortofill,andobserveflowatthedraintube.Oncethereisflow,checkthattherearenoleaksinsidethesensorenclosure.Thesensorisnowreadyfornormaloperation.

5.3 5000TOCi Guided Setup

Oncesampleflowisestablished,the5000TOCiisreadytobegintakingmeasurements.AccesstheGuidedSetupmenuintheM800bypressingtheConfigure(C)iconontheM800transmitter.Forinstructionsonbasicconfigurationofthe5000TOCiandM800,pleaserefertothe5000TOCiQuickStartGuide.AprintedcopyofthQuickStartGuideisprovidedwiththe5000TOCi.Acopyofthe QuickStartGuideisalsoprovidedontheOperatingManualCDprovidedwiththe5000TOCisensor.

5.4 Normal Operation

Undernormaloperatingconditions,the5000TOCiSensoriscontinuouslyrelayinginformationtoandfromtheM800.TheM800displayalsoactsasadisplayandstatusindicatorforthesensor.TheM800canbeconfiguredfor1-channel,2-channel,4-measurementor8-measurementmode.PleaserefertotheM800operatingmanualformoredetailonthesedisplaymodes.

IfanERRORorFAULTconditionisdisplayedontheM800,theMessagesmenucanbeusedtoretrievemoreinformationregardingthecauseofthecondition.TheMessagesmenuisaccessiblebypressingtheISMicon(i)andselectingMessages.Alternatively,theflashingRedorYellowcoloredbarontheM800canbepressedtobetakendirectlytothemessagesscreen.

5.5 Calibration

SystemSuitability,TOCandConductivityCalibrationTestKits(p/n58091559and58091566)are

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availableforthe5000TOCiSensor.The5000TOCiSensorFullCalibrationSOP(p/n58130257)describesthesecalibrationsindetail.Calibrationstandards(p/n58091259or58130568)arealsoavailable.ContactMettler-ToledoThorntonCustomerServicefororderinginformation.

NOTE:ItisrecommendedthataTOCcalibrationbeperformedaftereveryUVlampchange,andnottoexceed1year.Afullcalibrationisrecommendedannually.

5.5.1 TOC Calibration Methods

TherearefourmainTOCcalibration“types”available:• Standard• Extended• 1-pointslope(orspan)• 1-pointoffset

Standard: Formostapplicationsthatoperateoverawidedynamicrange,theStandardTOCcalibrationtypeisrecommended.AstandardcalibrationrequirestwoTOCcalibrationsolutions,typicallyat250ppband500ppb.Twocalibrationmultipliersandaddersaredeterminedintherangeof0to250ppbTOCand250to500ppbTOC.Thetwolinesintersectat250ppb.Thiscalibrationtypeisrecommendedforapplicationsrequiringaccuracyupto1000ppbCTOC.

Extended: Forapplicationsrequiringaccuracyupto2000ppbC,theExtendedTOCcalibrationtypeisrecommended.AnExtendedcalibrationutilizesthreeTOCcalibrationsolutions,typicallyat250ppbC,500ppbCand2000ppbC.Threecalibrationmultipliersandaddersaredeterminedintherangeof0-250ppbC,250-500ppbCand500-2000ppbC.

1-point slope:A1-pointslopecalibrationmethodwilladjusttheTOCcalibrationmultiplier.Ifastandardorextendedcalibrationisbeingusedwithyour5000TOCiandthe“1pointslope”is performed,itwillover-writetheactivecalibration.

1-point offset:ThismethodwilladjustthetheTOCcalibrationadder.Ifastandardorextendedcalibrationexistsandthe“1pointoffset”isperformed,itwillmodifytheadderonthe0–250ppbrange.TheTOCcalibrationstandardconcentrationusedforthe“1-pointoffset”mustbelowerthanthemidpointofthestandardcalibrationor50ppb,whicheverislower.ThismethodisrecommendedforapplicationswhereverylowTOCispredominantlyexpected.Thiscalibrationwillnotaffectthe TOCmultipliers.

5.5.2 Enter Calibration Mode

WhileinMeasurementmode,pressthec iconandselectCalibrateSensor.Usingtheappropriatedrop-downselectorsfromtheM800,selectthechannelassociatedwiththedesiredTOCsensor,andselecttheunitassociatedwiththeparameter(TOC,Conductivity,TemperatureorFlow)tobecalibrated.Then,selectthespecificinternalsensorstobecalibrated(conductivityandtemperatureonly),andthecalibrationtypetobeperformed.

Foradetailedexplanationonhowtoperformacalibrationa5000TOCicalibration,pleaserefertotheStandardOperatingProcedurePartNumber58130257.

h NOTE:DuringCalibration,agreenflashing”H”onthedisplayindicatesacalibrationisinprocesswithaHoldconditionactiveonthesensorassociatedwiththeindicatedmeasurement.RefertotheM800OperatingManualfordetailsontheoperationofthecalibrationholdfunction.

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5.6 System Suitability Testing

Inmostpharmaceuticalwaterapplications,SystemSuitabilityTestingisrequiredbyvariousregulatingorganizationssuchastheUnitedStatesPharmacopoeia(asstatedinUSP<643>)andEuropeanPharmacopoeia(asstatedinEP2.2.44)toqualifyinstrumentsusedfortotalorganiccarbon(TOC)measurements.TheSystemSuitabilityTestandTOCCalibrationKits(p/n58091559or58091566)forthe5000TOCiSensorareavailabletomeetthisrequirement.The5000TOCiSystemSuitabilityStandardOperatingProcedure(p/n58130258)describestheSystemSuitabilityTestingprocedureindetail.SystemSuitabilityStandards(P/N58091526)arealsoavailable.ContactyourlocalMETTLERTOLEDOCustomerServicerepresentativefororderinginformation.

h NOTE:SystemSuitabilityTestingshouldbeperformedaccordingtoindividualuserpolicy.ASystemSuitabilityTestisrecommendedaftereachUVlampchange.

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6 5000TOCiandM800ConfigurationThissectiondiscussesM800menusneededforconfiguationoffeaturesuniquetothe5000TOCi.ForinformationonuseofgeneralmenusassociatedwithM800setupwhicharenotcoveredhere,pleaserefertotheM800TransmitterOperatingManual.

6.1 Channel Setup

(PATH:C/Measurement/ChannelSetup)

TheChannelSetupfuntionallowsconfigurationoftheindividualmeasurementswhichwillbevisibleontheM800displayareaassociatedwiththeselectedsensorchannel.Forthe5000TOCi,the followingmeasurementoptionsmaybeselected:

TOCDisplaysTOCconcentrationinppt,ppborppm.

gC/LDisplaysTOCconcentrationinmg/LC,ug/LC,andng/LC.

Conductivity/RestivityInletsampleconductivity/restivitymaybedisplayedinohm-cm(MegaorKilo),S/cmorS/m(Mili,MicroorNano).

TemperatureInletsampletemperaturemaybedisplayedin°Cor°F.

LampRemaininglampoperatinghourswillbedisplayed,includingacoloredbarprovidingavisualindicationoflampliferemaining.

TOCave or gC/Lave

TheaverageTOCconcentrationoverauser-specifiedtimeframewillbecalculatedanddisplayedbythe M800. TOCaveiscalculatingonamovingtime-periodwhichcanbesetfrom1to24hours.

TOCpk or gC/Lpk

ThepeakormaximumTOCconcentrationrecordedwithinauser-spedifiedperiodfrom1to24hourswillberecordedanddisplayedbytheM800.TOCpkisdeterminedoveramovingtimeperiodasspecifiedbytheuser.

NOTE: AverageandPeakTOCconcentrationcanbeusedtoprovideasummarizedrepresentationofsystemwaterqualityoverauser-specifiedtimeperiodofupto24hours.Thesereadingsallowtheuseoftwodatapointstorepresenttheoverallwaterquality(averageTOCconcentration)andpoorestwaterquality(maximumTOCconcentration)presentduringthespecifiedtimeperiod.Thisavoidstheneedtoreviewseveralhoursofdatawhendocumentingthatwaterissafeforrelease,greatlysimplifyingthequalitydatacollectionprocess.

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6.2 Parameter Setting

(PATH:C/Measurement/ParameterSetting)

FromtheactivatedM800display,presstheConfigureicon(C),selectMeasurement,thenselectParameterSetting.Fromthechannelselectorpull-downlist,selectthechannelassociatedwiththe5000TOCitobeconfigured.Thefollowingfeaturescanbeconfiguredfromthismenu:

LampEnergizeorde-energizetheUVlamp.Select‘On’toenergizetheUVlamp.Select‘Off’tode-energizetheUVLamp

AutoStartTheAutoStartfeatureallowsthe5000TOCiSensortoautomaticallyresumenormaloperationfollowingapowerfailureorfaultcondition.ThefactorydefaultsettingfortheAutoStartfunctionis‘Off’.Thereforeduringinitialstart-up,theM800willidentifythesensorasa5000TOCiSensor,yetwillnotstartaTOCmeasurement.TostartaTOCmeasurement,theUVLampmustbemanuallyenergized.Oncethe‘AutoStart’modeissetto‘On’,itisnolongernecessarytomanuallyenergizetheUVLamp.

Select‘On’toactivatetheAutoStartfeature,allowingtheTOCsensortoautomaticallyresumeoperation.Select‘Off’torequiremanualactivationoftheUVLampfollowingapowerlossorfaultcondition.Therecommendedsettingin‘On’.

Key LockKeyLockwilldeactivatetheUVlampcontrolbuttonlocatedonthe5000TOCi.TheSensorKeyLockoptioncanbesetto‘On’or‘Off’.Thedefaultsettingis‘Off’.Tode-activatetheKeypadattheSensor,setthe‘KeyLock’optionto‘On’.ThisfunctioncanbeusedtoavoidinadvertentlyturningtheUVlampoffatthesensorundernormaloperatingconditions.

MeasurementThe5000TOCiprovidestwoderivedTOCmeasurements;AverageTOCandPeakTOC.ThesemeasurementsprovideanaverageofallTOCreadings,orthemaximumTOCreading,determinedoveraspecifiedtimeperiod.TheMeasurementoptioninthismenuallowsresettingthePeakandAverageTOCmeasurementstorestartthetimeperiodoverwhichthesevaluesaredetermined.

Tore-setthesemeasurementstoTimeZero,presstheMeasurementResetbutton,selectthemeasurement(s)tobereset,thenpresstheeicon.ThepeakandaverageTOCdeterminationwillimmediatelyrestart.

Cond LimitTheConductivityLimitallowsconfiguringthesensortoalerttheoperatorwhenthespecifiedlimitisexceededbygivinganerrorindicationandmessage.Thelimitsareselectable,andmustbesetabove0.0.Toactivatethislimit,setthedrop-downselectorto‘On’thenspecifytheconductivityvalueatwhichtheerrormessagewillbereceived.Thedefaultvalueis2uS/cm.

AutobalanceThe5000TOCiSensoriscapableofautomaticallybalancingthetwoconductivitysensors.Thisstepisperformedtoaccountforsmalldifferencesinconductivitymeasurementbetweenthetwoconduc-tivitysensors.ThedefaultfactoryconditionoftheAutoBalancefeatureofthe5000TOCiSensoris‘Off’.ThiswillresultinnoAutoBalanceactivitybeingperformedautomatically.Theusermaychangethisattributeto‘On’atanytime.ForapplicationswithverylowTOC(<5ppb)ANDhighresistivity(>15Mohm-cm),itisadvisedtosetthisfeatureto‘On’forimprovedaccuracy.Forapplicationsthatdonotmeetbothcriteria,suchaspharmaceutical-gradewaterproduction,theusermayelecttosettheAutoBalancefeatureto‘Off’withlittleobservableeffect.

5000TOCi Sensor 21


ToactivatetheAutobalancefeature,select‘On’intheAutobalancedrop-downmenu.Press‘Configure’toopenawindowforsettingtheAutobalancecharacteristicsdescribedbelow:

CycleTime:SetatimeintervalfortheAutobalancetooccurautomatically.Thisvalueisselectablefrom24to4500hours,withafactorydefaultsettingof4500hours.Notethatthetimeremaininguntilthenextautobalanceoccurscanbeviewedunderi\iMonitor.

Limit:Setthetoleranceforbalancingthesensors(limitin%).ThisisthepercentagedifferenceallowedbetweenthetwoconductivitysensorreadingsduringanAutobalancecyclewhenthelampisoff.

RinseTime:Setthelengthoftimethatthe5000TOCisensorwillhavesamplewaterflowingthroughitbeforeperformingtheAutobalancefunction.TheRinseTimecanbesetfrom1to999minutes.DuringtherinseandAutobalanceprocess,theUVlampwillbeturnedoff,andthesensorwillnotprovideaTOCindication.

Hold:Seta‘holdlastmeasurement’conditionsotheanalogoutputsandrelaysareheldinthecurrentstatewhileanAutobalanceisperformed.

Tomanuallyinitateanautobalancesequenceoutsideoftheautomaticcycletime,usetheAutobalanceNowfeature.SetAutobalanceto‘On’,thenpressthe‘Start’buttonlocatedonintheTOCMaintenancemenu.AccesstheTOCMaintenancemenubypressingc/TOCMaintenancefromtheM800mainscreen.

AccessoryTheaccessorysettingoveridestheautomatedflowcontrolfeaturewithinthe5000TOCi,andsetstheflowcontrolvalvetofullyopen.Forlowpressureapplications,apumpmaybenecessarytoprovideadequatepressuretothe5000TOCiinordertoachieveaflowrateof20ml/min.Mettler-ToledoThorntonoffersametered,positivedisplacementPumpModule(P/N58091565)asanaccessoryforapplicationswhereapumpisrequired.

WhenthePumpModuleisinstalled,select‘Pump’intheAccessorydrop-downmenu.

MeasureMeasureassignstheprimarymeasurementassociatedwiththeTOCchannel.Theselectedparameterwillbetheprimarymeasurement,andwillbethefirstmeasurementdisplayedwithintheassociatedchanneldisplaysontheM800transmitter.Tochangetheprimarymeasurement,selecttheappropriatemesurementfromthe‘Measure’drop-downmenu.

6.3 ISM Setup

(PATH:C/ISMSetup)

TheISMSetupmenuallowsconfigurationofvariousISMfeaturesassociatedwiththe5000TOCi. Thesefeaturesare:

Set IntervalsTheM800iMonitorprovidesanintuitive,graphicuserinterfacewhichallowsquicklyandintuitivelyassessingthegeneralhealthoftheassociatedsensorbydisplayingaseriesofcoloredbarswhichdepictsthetimeremainingbeforespecificeserviceproceduresmustbecompleted.The‘SetIntervals’menuallowsdefiningthetimeintervalforconductingtheseservicesteps.

CalibrateTOC:Definethemaximumtimeperiodinhoursbeforeacalibrationmustbeperformed.

5000TOCi Sensor 22


PerformSST:DefinethemaximumtimeperiodinhoursbeforeanSSTshouldbeperformed.

ReplaceFilter:Definethemaximumtimeperiodinhoursbeforethehighcapacityinletfiltermustbereplaced.

LampLimit:DefinethemaximumtimeperiodinhoursbeforetheUVlampmustbereplaced.

Reset CountersThe5000TOCiprovidestheabilitytocountthenumberofoccurenceswhereselectparametersriseaboveorfallbelowuser-specifiedvalues.ThetotalnumberofoccurencesistrackedbytheExcursionCounterfeature,fullydescribedintheISMDiagnosticssectionofthismanual.TheResetCountersoptionallowsettingthesecountersbacktozero.

Toresetthesecounters,pressthedrop-downselectorassociatedwiththecounterwhichistobereset,andselect‘Yes’fromthelistthatappears.Repeatthisprocessforeachcountertobereset.Onceallcountershavebeenselected,presstheeicon.Thevalueforeachcounterselectedwillbesetbacktozero.

Thelimitsforthesecountersmaybesetusing‘SetExcursionLimits’notedbelow.

Set Exc. (Excursion) LimitsThe5000TOCiSensoriscapableofautomaticallytrackingthenumberofoccurencswhereselectparametersriseaboveorfallbelowuser-definedvalues.TheSetExcursionLimitsfeatureallowsdefiningthethresholdvaluesforthefollowinglimitcounters:

HighTOCHighConductivityHighTemperatureHighFlowLowFlow

6.4 ISM / Sensor Alarm

(PATH:C\ISM/SensorAlarm)

TheISM/SensorAlarmfeatureallowsconfiguringanalarmrelaytoprovideanexternalindicationofselectedalarmconditions.Whenanyoftheselectedeventsoccur,aFlashingRedBarwillbedisplayedontheM800,andthealarmrelaywillenergizeifconfigured.

Forthe5000TOCi,thefollowingalarmconditionsmaybeselected:

SensorDisconnected:Theselectedalarmrelayisactivatedwhenthe5000TOCibeceomesdisconnectedfromtheM800transmitter.

LampOff:Theselectedalarmrelayisactivatedifthe5000TOCiUVlampitturnedoffforanyreason.

TTCal=0:Theselectedalarmrelayisactivatedwhentheremainingtimeuntilthenextcalibrationreaches0Hours.

LampTime=0:Theselectedalarmrelayisactivatedwhentheremaininglamplifereaches0Hours.

5000TOCi Sensor 23


TTSST=0:TheselectedalarmrelayisactivatedwhentheremainingtimeuntilthenextSystemSuitabilityTestreaches0Hours.De-selectingtheevenwillalsodeactivatetheiMonitorindication.

Filter=0:TheselectedalarmrelayisactivatedwhentheremainingtimeuntilthenextSystemSuitabilityTestreaches0Hours.De-selectingtheevenwillalsodeactivatetheiMonitorindication.

6.5 Reset

(PATH:C/Reset)

TheM800providestheabilitytoresetvarioussettingswithinconnectedsensorstofactorydefaultvalues.Toresetparametersassociatedwiththe5000TOCi,entertheResetmenuandselectthechannelassociatedwiththe5000TOCitoberesetfromthedrop-downselectorprovided.Toconfiguretheresetfunction,pressthe‘Configure’button,selectthespecificparametersetsthataretoberesettothefactoryvalues,andpresstheeicon.

FromthemainResetscreen,a‘Reset’buttonwillnowbevisible.Toresettheselectedparametersets,press‘Reset’andthenpress‘Yes’intheacknowledgementdialogueboxthatappears.

Thefollowingparametersetsassociatedwiththe5000TOCimaybereset:

SensorCal:Theoriginalfactorycalibrationwillberestoredforallinternalmeasurementparameters(TOC,Conductivity,TemperatureandFlow).

ElecCal:Theelectronicscalibrationforconductivitywillberestoredtotheoriginalfactorysettings.

SensorSetup:Allsensorsetupparametersexcludingcalibrationvalueswillberestoredtofactorysettings.

6.6 ISM Diagnostics

(PATH:i/ISMDiagnostics)

TheISMDiagnosticsmenuallowsviewingmanycharacteristicsofthe5000TOCitoallowassessingthegeneralconditionofthesensor.

Service InvervalTheServiceIntervalscreenwilldisplaytherequireddateonwhichthenextCalibration,SystemSuitibilityTest,UVLampReplacementandhighcapacityInletFilterReplacementmustbeconducted,basedonthesettingsconfiguredinthe‘SetIntervals’section,describedabove.

UV LampOperatingparametersassociatedwiththeUVlampcanbeviewedfromtheUVLampdiagnosticscreen.Theseparametersinclude:

UserID:DisplaystheuserIDthatwasactivewhenalampchangewaslastregisteredthroughtheTOCMaintenancemenu.NotethattheUserIDisrecordedonlyifPasswordProtectionisturnedonintheM800transmitteratthetimethelampchangeisregistered.Ifpasswordprotectionisnotturnedon,thennouserIDwillberecorded.

Remain:DisplayshoursofoperationremainingonthecurrentUVLampbasedupontheLampLimit

5000TOCi Sensor 24


settingunderISMSetup.ThisvalueisresettotheLampLimitsettingwhenalampreplacementisregisteredthroughtheTOCMaintenancemenu.

LastChanged:Indicatesthedateoflastlampchange,basedupontheM800internalclocksettingatthetimeaUVlampreplacementisregisterdthroughtheTOCMaintenancemenu.

ChangeCycles:Indicatesthetotalnumberoflampreplacementsperformedoverthelifeofthesensor.ThiscounterisincrementedwhenalampreplacementisregisteredthroughtheTOCMaintenancemenu.

PowerCycle(Today):Numberofon/offcyclesexperiencedbythelampduringthecurrentcalenderday.Thiscounterwillautomaticallyresettozeroatmidnight,asdeterminedbytheM800internalclock.ThiscountermayalsobemanuallyresetfromtheTOCMaintenancemenu.

PowerCycle(Lifetime):Numberofon/offcyclesexperiencedbytheUVlampduringthelifeofthecurrentUVLamp.ThecounterisresettozerowhenalampchangeisrecordedintheTOCMaintenancemenu.

WhenaUVlampreplacementisregistered(SeeTOCMaintenancebelow),theUserIDactiveatthetimethelampchangeisregisteredwillberecorded(onlyifPasswordprotectionisturnedonattheM800),theChangeCyclesvalueisincrementedby1,the‘LastChange’dateissettothecurrentdate(basedontheM800internalclock),thehoursreamainingissettotheLampLifeLimit,andthepowercyclecountersareresettozero.

Exc. CountersThe5000TOCiSensoriscapableofautomaticallytrackingthenumberofoccurenceswhereselectparametersriseaboveorfallbelowuser-definedvaluesasdescribedintheSetExcursionLimitssectionabove.TheExcursionCountersscreenallowsviewingthetotalnumberofexcursionsthathaveoccurredforthefollowingconditionsbasedonthevaluesenteredinSetExcursionLimits:

HighTOCHighConductivityHighTemperatureHighFlowLowFlow

Filter InfoOperatingparametersrelatedtothehighcapacityinletfiltercanbeviewedfromtheFilterInfoscreen.Theseparametersinclude:

UserID:DisplaystheuserIDthatwasactivewhenafilterreplacementwaslastregisteredthroughtheTOCMaintenancemenu.NotethattheUserIDisrecordedonlyifPasswordProtectionisturnedonintheM800transmitteratthetimethefilterreplacementisregistered.Ifpasswordprotectionisnot turnedon,thennouserIDwillberecorded.

Remain:DisplayshoursofoperationremainingonthecurrentinletfilterbasedupontheReplaceFiltersettingunderISMSetup.ThisvalueisresettotheReplaceFiltersettingwhenafilterreplacementisregisteredthroughtheTOCMaintenancemenu.

LastChanged:Indicatesthedateoflastfilterreplacement,basedupontheM800internalclocksettingatthetimeafilterreplacementisregisteredthroughtheTOCMaintenancemenu.

ChangeCycles:Indicatesthetotalnumberoffilterreplacementsperformedoverthelifeofthesensor.ThiscounterisincrementedwhenafilterreplacementisregisteredthroughtheTOCMaintenancemenu.

5000TOCi Sensor 25


6.7 Calibration Data

(PATH:i/CalibrationData)

The5000TOCiwillstoreupto4setsofcalibrationdataincludingthefactorycalibration(Factory),thecurrentactivecalibration(Actual),anduptotwoofthemostrecentpreviouscalibrations(Cal1andCal2,withCal1beingthemostrecenthistoricalcalibrationrecord).EachofthesecalibrationrecordscanbeviewedfromtheM800.

Toviewanyofthesecalibrationrecords,selectthechannelassociatedwiththeapplicable5000TOCi,thecalibration,andtheparametertobereviewedfromthedrop-downselectorsprovided,thenpresstheCalDatabutton.Usethe<and>iconstochangepagestoviewtheentirecalibrationrecord.Onceviewingoftherecordiscompleted,presstheeicontoreturntotheCalibrationDatascreen.

6.8 SST Information

(PATH:i/SSTInfo)

The5000TOCiwillstoreupto4setsofSystemSuitabilityTestresultslabeledSST-1(mostrecent)throughSST-4.TheresultsofeachoftheseSSTprocedurescanberetrievedthroughtheM800transmitter.

ToviewanyoftheseSSTrecords,selectthechannelassociatedwiththeapplicable5000TOCisensorandtheSSTresulttobeviewedfromthedrop-downselectorsprovided,thenpresstheSSTDatabutton.Use the <and>iconstochangepagestoviewtheentireSSTrecord.Onceviewingoftherecordiscompleted,presstheeicontoreturntotheSSTInfoscreen.

6.9 TOC Maintenance

(PATH:c/TOCMaintenance)

TheTOCMaintenancemenuallowsrecordingthecompletionofstandardmaintenancetasksthatarenotcontrolledthroughmenuoperation,aswellasaccesstocertainfeaturesthatmaybeneededduringsystemmaintenance.ThesefeaturesincludeUVLamporInletFilterReplacement,displayormanualcontrolofTOCSensorsampleflowrate,orresettingtheLampPowerCyclesTodaycounter.Operationssuchascalibrationandsystemsuitabilitytestingareautomaticallyrecordedatthecompletionofthesetasks.

Replace LampPressthe‘Change’buttonafterperformingaUVlampreplacementtoupdatetheinformationrelatedtotheUVlampunderISMDiagnostics.

5000TOCi Sensor 26


Lamp Power Cyc. TodayPress‘Reset’tosettheLampPowerCyclesTodaycounterbacktozero.

FlowAllowsdisplayingthecurrentflowratebasedupontheinternalflowmeasurement,ormanuallycontrollingoftheflowrate.

Manual:Press‘Manual’tomanuallysettheinternalflowcontroltoaspecificvalue.Theflowratewillbereturnedtoautomaticcontrolafterleavingthisscreen.

Display:Press‘Display’toviewthecurrentsampleflowrateasmeasuredusingtheflowsensorwithin the 5000TOCi.

Replace FilterPressthe‘Change’buttonafterperforminganinletfilterreplacementtoupdatetheinformationrelatedtotheinletfilterunderISMDiagnostics.

5000TOCi Sensor 27


7 5000TOCi Sensor Service RequirementsThe5000TOCiSensorisdesignedtominimizeserviceandmaintenance.Therearevirtuallynomovingmechanicalcomponents,thereforenormaloperatingwearandtearisminimal.Thisreducestheamountofconsumablecomponentsaswellastheamountoftimeneededtomaintainthesensor.Listedbelowareinstructionsonhowtoperformsimpleperiodicmaintenance,whichincludesUV Lampchange(every4500hoursofoperation),filterreplacement(typicallyevery6months),andgeneralcleaning.

7.1 UV Lamp Replacement

WARNING: UV RADIATION HAZARDApplypowertoUVlamponlywheninstalledinhousinginaccordancewithinstructionmanual.DONOTremoveUVlampfromhousingunlesspowerisoff.Always protect eyes and skin from direct exposure to UV light.

Mettler-ToledoThorntonrecommendsreplacementoftheUVlampinsidethe5000TOCiSensorafter4500hoursofoperation,or6monthsofcontinuoususe,nottoexceedoneyear.Thisisasimpleprocedurethatrequiresonlyafewminutestocomplete.ThefollowingstepsexplaintheproperprocedurefortheUVlampreplacement.Refertotheillustrationbelow.

CAUTION:UseofaUVlampotherthanthoseprovidedbyMettler-ToledoThorntonspecificallyforusewiththe5000TOCiSensorwillaffectperformanceandvoidthewarrantyofthisproduct.

1 Atthesensor,turnofftheUVlampbypressingthelampcontrolbutton(UVlampONLEDwillturnoff).IftheLEDdoesnotturnoff,checkthattheSensorKeyLockisintheoffpositionintheM800.RefertoC\ParameterSettings:SensorKeyLockfunctioninthismanual.

2 OncepowertotheUVlampisoff,openthefrontcoverofthesensorenclosurewiththefrontcovertool.

3 Removethesidecoverlabeled‘UVLAMPREPLACEMENTCOVER’ontheleftsideofthesensor enclosure.Usealarge-bladedflat-headscrewdriverandturnthecovercounterclockwiseto loosenandunscrewthecover.

4 DisconnectthepowercabletotheUVlamp.Thisconnectorislocatedonthebacksideofthefrontcover,abovethecircuitboard.

5 LoosenbutdonotremovetheUVlampholdingscrewlocatedontheleftsideoftheoxidationchamber.

6 SlidethecableoftheUVlampthroughthesideopeningoftheenclosureandgentlyslidetheUVlampoutoftheoxidationchamberassembly(stainlesssteelcylinder).BecarefulnottolettheUVlamphitthequartzglasscoilinsidethechamber.

7 Usetheglovessuppliedwitheachreplacementbulb.Holdthenewlampfromtheendsofthelamp.Donottouchtheclearglassportionofthebulb.SlidethenewUVlampintothesideopeningoftheenclosureandintotheoxidationchamberopeninguntilitstops.DonotuseexcessiveforcetoinserttheUVlampasthismaycausedamagetothelamportheinternalcomponentsofthe oxidationchamber.

8 TightentheUVlampholdingscrewuntilsnug.

a

a

5000TOCi Sensor 28


CAUTION: Donotovertightenholdingscrew.

9 Feedthepowercablethroughthesideopeningoftheenclosure.Re-connectthecabletothepowerconnectoronthefrontdoor.

10Closefrontcoverofthesensorandsecurefastenerswiththefrontcovertool.

11InstalltheUVLampreplacementcoverontheopeningonthesideoftheenclosure.

12AttheM800,entertheTOCMaintenancemenuatPath:c/TOCMaintenanceandpressthe ReplaceLampbuttontoregisterthelampreplacement.

13Afterthelampreplacementhasbeencompleted,aTOCcalibrationmustbeperformed.Inaddition,aSystemSuitabilityTestisrecommendedforapplicationswherecompliancewithPharmacopeiaregulationsisnecessary.PleaserefertotheStandardOperatingProceduresforCalibration(P/N58130257)andtheStandardOperatingProcedureforSystemSuitabilityTesting(P/N58130258)formoredetailontheseprocedures.

7.2 Front Panel Cleaning

Cleanthefrontpanelwithadampsoftcloth(wateronly,nosolvents).Gentlywipethesurfaceanddrywithasoftcloth.

7.3 Technical Support

Fortechnicalsupportandproductinformationforthe5000TOCi,contactyourlocalMettler-Toledo SalesOfficeorrepresentative.

a

5000TOCi

5000TOCi Sensor 29


7.4 High Capacity Inlet Filter Replacement

The5000TOCiSensorincludesahighcapacityfilter(shownbelow)containingafilterelementthatshouldbereplaced(P/N58091551,packageof2)afterapproximately6monthsofoperation,dependingonwaterqualityconditions.Detailedinstructionstoreplacethisfilterareincludedinthereplacementpackage.

Oncethefilterreplacementhasbeencompleted,thereplacementmustberegisteredwiththe5000TOCitoresetthefilteroperatinginformation.AttheM800,entertheTOCMaintenancemenuatPath:c/TOCMaintenanceandpresstheReplaceFilterbuttontoregisterthefilterreplacement.

7.5 Draining and Shipping Instructions

The5000TOCicontainsaglasscoilwhichfacilitatesoxidationofthewatersample.Waterfreezingwithinthecoilduringtransportationwillcausethiscoiltobreak.Therefore,itisimportantthatall waterberemovedfromtheTOCsensorpriortoshipment.

Todrainthewater,connecttheTOCsensortoACpower.Toputtheflowcontrolvalveintothe‘Drain’mode,pressandholdtheUVLampbuttonfor5secondsuntiltheSensorStatusLEDbeginsflashing.Thismodewillfullyopentheautomaticflowcontrolvalvetoallowdrainingthesensormoreeasily.Oncethevalvehasbeenplacedintothe‘Drain’mode,usethesuppliedplasticsyringetopushthewateroutofthesensor,blowingfromtheinlet,andpushingwateroutthroughthesensoroutlet.

5000TOCi Sensor 30


8 Troubleshooting the 5000TOCi Sensor

8.1 Basic Troublshooting

Listedbelowaresometechniquesthatmayassistintroubleshootingthe5000TOCi.RefertotheFaultandErrorMessageTablesonthenextpageformessagesthatappearintheM800messagesmenuwhenaFaultorErrorconditionexists.

Problem PossibleCause

NoneoftheLEDsilluminate •LED/Keypadfailure•Circuitboardfailure•NoACPoweravailableto5000TOCi

NoFlowfromsensorsampleoutlet •Highcapacityinletfilterclogged•Flowcontrolvalvefailure•Sampleflowshutofftosensorinlet•Internalcomponentleaking•Samplefeedpressuretoolow

Erraticflowthroughthesensor •Sampleoutlettubingnotinstalledpermanufacturer’sinstructions•FlowControlvalvefailure•Erraticwatersystem/samplefeedpressure

8.2 Fault and Error Messages

WhenanErrororFaultconditionexists,theM800willdisplayared(fault)oryellow(error)flashingbaratthetopofthechanneldisplayfortheaffectedsensor.Iftheaffectedsensorchannelisnotcurrentlydisplayed,theflashingbarwillappearatthetopofthedisplay.TheFaultorErrordescriptioncanbefoundintheM800messagesmenu.Themessagemenucanbeaccessedbypressingthecoloredbar,orbypressingtheiiconandselectingtheMessagesmenuoption.Themessagesassociatedwiththe5000TOCiSensorarelistedinthefollowingtables.ThefirstcharacterofthemessagewillbeanFtoindicateafaultandanEtoindicateanerror.AfaultconditionwillimmediatelydisabletheTOCindication.Afterbeingactivefor30seconds,aFaultwillturnofftheUVlampatthe5000TOCiSensor.FaultscausetheM800tocontrolrelaysandanalogoutputstothedefinedfail-safecondition,i.e.,onfaultsetminimumormaximum.

5000TOCi Sensor 31


Fault Message Table

Message Displayed Description Action

F-UVLampFailure UVlampnotlitwhenpoweredup Checklampconnectionsorreplacelamp

F-Noflowdetected Flow<12ml/min=nofloworflowsensorfailed

ChecksupplyisolationvalveChecksamplesupplypressureCheckforobstructioninwaterlineReplaceHighCapacityInletFilter

F-C1shorted C1failure(sensororcable) ReplaceC1

F-C2shorted C2failure(sensororcable) ReplaceC2

F-C1open C1failureornowater Checkforflow.ReplaceC1

F-C2open C2failureornowater Checkforflow.ReplaceC2

F-T1open/shorted T1failure(sensororcable) ReplaceC1

F-T2open/shorted T2failure(sensororcable) ReplaceC2

F-Conductivityhigh Inputconductivity>100μS/cmcompensatedonC1

Investigatecauseonincreasedconductivityfromsamplesupply

F-Communication CommunicationfailurebetweenM800TOCand5000TOCi

Usermustcorrect

F-TempHigh TemperatureatT1>95°C. ReduceinlettemperatureInstallsampleconditioningcoil

F-SecondaryMicro(AVR)Fails

FailureofAVRMicroprocessor ReplaceSensorPCBAContactMettlerToledo

AnErrorisgeneratedbyaconditionthatmaycauseaproblemwiththeproperoperationofthesensor.Underanerrorcondition,thesensorwillcontinuetomakemeasurementsbutthemeasuredvaluemaybeinerrordependinguponthecauseoftheerrormessage.

5000TOCi Sensor 32


Error Message Table

Message Displayed Description Action

E-UVlampovertime LampLimittimeexceeded ReplaceUVLampRegisterlampchangeatM800

E-AutoBaltoohigh AutobalanceValueHigh Turnlampoff,flushsystem,andrestartAutobalance

E-Can‘tstartrinse Can‘tStartAutobalance Checksamplesupply

E-NVRAMfailure Can‘tcommunicateorChecksuminvalid

Repairsensor.Willworkwithdefaultsettings.Setbysensor.

E-Flowtolow Flowratebelow15mL/min ChecksamplesupplyReplaceinletfilterCheckforobstructioninwaterline

E-Flowtoohigh Flow>25mL/min ControlValveFailure

E-Conductivitylow Inputconductivity<0.050μS/cmcompensatedonC1

Usermustcorrect

E-CondOverLimit ConductivityLimitexceededasdefinedinTOCParameterSettings

Investigatecauseforhighconductivityinsamplewater

E-Temphigh TempOverrange>90°CatC1

ReducesampleinlettemperatureInstallSampleConditioningCoil

E-Templow Temperaturedetected<2°CatC1

Usermustcorrect

E-TOCoverrange TOC>3ppm

E-CalibrationIncomplete Calibrationnotsavedsucessfullyduetopowerlossorcommunicationlosswhilesaving

Repeatcalibrationprocess.Sensorwillautomaticallyresumeoperationwithpreviouscalibration.

5000TOCi Sensor 33


9 Accessories and Spare PartsPleasecontactyourlocalMettler-ToledoSalesofficeorrepresentativefordetailsforadditionalaccessoriesandspareparts.

9.1 M800 Transmitter

Description Order no.PatchCord,1ft(0.3m) 58 080 270PatchCord,5ft(1.5m) 58 080 271PatchCord,10ft(3.0m) 58 080 272PatchCord,15ft(4.5m) 58 080 273PatchCord,25ft(7.6m) 58 080 274PatchCord,50ft(15.2m) 58 080 275PatchCord,100ft(30.5m) 58 080 276PatchCord,150ft(45.7m) 58 080 277PatchCord,200ft(61.0m) 58 080 278PatchCord,300ft(91.4m) 58 080 279

9.2 5000TOCi Sensor Accessories and Spare Parts

Description Order no.PumpModule 58 091 565

Kit,tool,4000TOC/5000TOCSensor(Includes5/16"(8mm),3/8"(9.5mm),7/16"(11mm)wrenchesandoffsetscrewdriver

58 091 520

PipeMountingKit,1-1/2"(3.8cm)pipe 58 091 521

PipeMountingKit,2"(5cm)pipe 58 091 522

PipeMountingKit,3"(7.6cm)pipe 58 091 523PipeMountingKit,4"(10cm)pipe 58 091 524

Kit,CalibrationandSystemSuitabilityTestwithSmartconductivitysensor(SSTandcalibrationstandardssoldseparately)

58 091 559

Kit,CalibrationandSystemSuitabilityTestwithUniCond®Sensor(SSTandcalibrationstandardssoldseparately)

58 091 566

Adapter,0.25"(6mm)tubeto0.125"(3mm)tube,compressiontype 58 091 540Adapter,0.125"(3mm)O.D.tubeX0.25"(6mm)male-NPTconnector 58 091 541Adapter,0.125"(3mm)O.D.tubeX0.25"(6mm)female-NPTconnector 58 091 542

Adapter,0.125"(3mm)tubeTO0.5"(13mm)316stainless-steelpipe(0.75"[19mm]TRI-CLAMPCONNECTION)

58 091 543

FilterAssembly,Highcapacity 58 091 550Highpressureregulator 58 091 552Stainlesssteeloutlettube 58 091 553

5000TOCi Sensor 34


9.3 5000TOCi Sensor Consumable Items

Description Order no.

Fuse,1.25A,SensorPCB(Foruseonboth110VACand220VACModels) 58 091 519

ReplacementUVLamp(recommendedevery4,500hoursofoperation) 58 091 513

SystemSuitabilityStandards(ForusewithCal/SSTKITP/N58091559and58091566)

58 091 526

CalibrationStandards(ForusewithCal/SSTKITP/N58091559and58 091 566)

58 091 529

CombinedCalibrationandSSTStandards(ForusewithCal/SSTKITP/N58091559and58091566;contains58091526and58091529)

58 091 537

CalibrationStandardsforExtendedRangeCalibration(ForusewithCal/SSTKITP/N58091559and58091566)

58 091 568

CombinedCalibrationandSSTSolutionsforExtendedRangeCalibration(ForusewithCal/SSTKITP/N58091559and58091566;contains58091526and58091568)

58 091 569

Filterelement,HighCapacity(Pkg.2) 58 091 551

5000TOCi Sensor 35


10 5000TOCi Sensor Default Settings

Parameters Sub Parameters Value Unit

Autobalance Parameters

Lamp Parameters

TOC General Parameters

Autobalance On / Off

Autobalance Cycle Time

Autobalance Limit

Rinse Time

Lamp Life Limit

AutoStart On / Off

Sensor Keypad Lock Yes / No

Override Cond. Limit Yes / No

Conductivity Limit

Off

4500

15

15

4500

Off

No

No

2.0

Hours

%

Minutes

Hours

µS/cm

5000TOCi Sensor 36


11 5000TOCiSpecificationsMeasurementRange 0.05-2000gC/L(ppbC)Accuracy ±0.1ppbCforTOC<2.0ppb(forwaterquality>15MΩ-cm) ±0.2ppbCforTOC>2.0ppband<10.0ppb(forwaterquality> 15MΩ-cm) ±5%ofmeasurementforTOC>10.0ppb(forwaterquality0.5to 18.2MΩ-cm)Repeatability ±0.05ppbC<5ppb,±1.0%>5ppbResolution 0.001ppbC(gC/L)AnalysisTime ContinuousInitialresponsetime <60secondsUpdateRate 1SecondLimitofDetection 0.025ppbC

Conductivity SensorConductivityAccuracy ±2%,0.02to20μS/cm;±3%,20-100μS/cmConstantAccuracy 2%TemperatureSensor Pt1000RTD,ClassATemperatureAccuracy ±0.25°C

Sample Water RequirementsTemperature 0to100°C*ParticleSize <100micronMinimumWaterQuality 0.5MΩ–cm(2µS/cm),pH<7.5**Flowrate 20mL/minPressure 4to100psig(0.3barto6.9bar)atsampleinlet connection***General SpecificationsOverallDimensions 11"[280mm]Wx8.8"[188mm)Hx5.25"[133mm)DSampleConnectionsInlet 0.125"[3mm]O.D.(6'[2m]FDAcompliantPTFEtubingsupplied)Outlet StainlessSteeldraintube (5'[1.5m]flexibletubingprovided)InletFilter 316SS,inline60micronWeight 5.0lb.[2.3kg]Enclosurematerial Polycarbonateplastic,flameretardant,UVandchemicalresistant UL#E75645,Vol.1,Set2,CSA#LR49336Wettedparts 316SS/Quartz/PEEK/Titanium/PTFE/Silicone/EPDMAmbientTemperature/ 5to50°C/5to80%Humidity,non-condensingHumidityratingPowerrequirements 100-130VACor200-240VAC,50/60Hz,25WMaximumWallMount Standard,mountingtabsprovidedPipeMount Optional,withpipe-mountbracketaccessory (fornominalpipesizes1"[2.4cm]to4"[10cm])MaximumSensorDistance300ft[91m]LocalIndicators FourLEDlightsforFault,Error,SensorStatusandUVLampONRatings/Approvals CECompliant,ULandcUL(CSAStandards)listed. ConductivityandtemperaturesensorstraceabletoNISTand ASTMD1125andD5391 MeetsASTMD5173StandardTestMethodforOn-LineMonitoringof CarbonCompoundsinWaterbyUVLightOxidation*Temperatureabove70°CrequiresSampleConditioningCoilp/n58079518(included).**Forpowerplantcyclechemistrysamples,pHmaybeadjustedbymeasurementaftercationexchange.***Processpressureabove85psig(5.9bar)requiresoptionalHighPressureRegulatorp/n58091552.

Specificationssubjecttochangewithoutnotice

5000TOCi Sensor 37


12 WarrantyMETTLERTOLEDOwarrantsthisproducttobefreefromsignificantdeviationsinmaterialandworkmanshipforaperiodofoneyearfromthedateofpurchase.Ifrepairisnecessaryandnottheresultofabuseormisusewithinthewarrantyperiod,pleasereturnbyfreightpre-paidandamendmentwillbemadewithoutanycharge.METTLERTOLEDO”sCustomerServiceDept.willdetermineiftheproductproblemisduetodeviationsorcustomerabuse.Out-of-warrantyproductswillberepairedonanexchangebasisatcost.

TheabovewarrantyistheonlywarrantymadebyMETTLERTOLEDOandislieuofallotherwarranties,expressedorimplied,including,withoutlimitation,impliedwarrantiesofmerchantabilityandfitnessforaparticularpurpose.METTLERTOLEDOshallnotbeliableforanyloss,claim,expenseordamagecausedby,contributedtoorarisingoutoftheactsoromissionsoftheBuyerorThirdParties,whethernegligentorotherwise.InnoeventshallMETTLERTOLEDO’sliabilityforanycauseofactionwhatsoeverexceedthecostoftheitemgivingrisetotheclaim,whetherbasedincontract,warranty,indemnity,ortort(includingnegligence).

5000TOCi Sensor 38


13 CertificateMettler-ToledoThornton,Inc.,36MiddlesexTurnpike,Bedford,MA01730,USAhasobtainedUnderwritersLaboratories’listingfor5000TOCiModelTOCSensors.TheybearthecULusListedmark,signifyingthattheproductshavebeenevaluatedtotheapplicableANSI/ULandCSAStandardsforuseintheU.S.andCanada

Declaration of Conformity

We,Mettler-ToledoThornton,Inc.36MiddlesexTurnpikeBedford,MA01730,USADeclareUnderoursoleresponsibilitythattheproduct:

5000TOCi Sensor

towhichthisdeclarationrelates,inconformitywiththefollowingEuropean,harmonizedandpublishedstandardsatthedateofthisdeclaration:

EMCEmissions:EN55011ClassA

EMCEmissionsandImmunity:EN61326-12006,MeasurementControlandLaboratoryequipmentEMCrequirements.

Safety:EN61010-12001-02,Secondedition

UL LISTING

US UL61010-1ElectricalEquipmentforMeasurement,ControlandLaboratoryUse

CAN/CSA CSA 22.2 No. 61010-1

Subjecttotechnicalchanges.©Mettler-ToledoThornton,Inc.09/13 Printed in USA. 58 130 246

Mettler-ToledoThornton,Inc.900MiddlesexTurnpikeBillericaMA,01821Tel.+1-781-301-8600,Fax+1-781-301-8701

METTLER TOLEDO Market Organizations

Sales and Service:

AustraliaMettler-Toledo Ltd.220 Turner StreetPort MelbourneAUS-3207 Melbourne/VICPhone +61 1300 659 761Fax +61 3 9645 3935e-mail [email protected]

AustriaMettler-Toledo Ges.m.b.H.Südrandstraße 17A-1230 WienPhone +43 1 604 19 80Fax +43 1 604 28 80e-mail [email protected]

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CroatiaMettler-Toledo d.o.o.Mandlova 3HR-10000 ZagrebPhone +385 1 292 06 33Fax +385 1 295 81 40e-mail [email protected]

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DenmarkMettler-Toledo A/SNaverland 8DK-2600 GlostrupPhone +45 43 27 08 00Fax +45 43 27 08 28e-mail [email protected]

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GermanyMettler-Toledo GmbHProzeßanalytikOckerweg 3D-35396 GießenPhone +49 641 507 333Fax +49 641 507 397e-mail [email protected]

Great BritainMettler-Toledo LTD64 Boston Road, Beaumont LeysGB-Leicester LE4 1AWPhone +44 116 235 7070Fax +44 116 236 5500e-mail [email protected]

HungaryMettler-Toledo Kereskedelmi KFTTeve u. 41HU-1139 BudapestPhone +36 1 288 40 40Fax +36 1 288 40 50e-mail [email protected]

IndiaMettler-Toledo India Private LimitedAmar Hill, Saki Vihar RoadPowaiIN-400 072 MumbaiPhone +91 22 2857 0808Fax +91 22 2857 5071e-mail [email protected]

ItalyMettler-Toledo S.p.A.Via Vialba 42I-20026 Novate MilanesePhone +39 02 333 321Fax +39 02 356 [email protected]

JapanMettler-Toledo K.K.Process Division6F Ikenohata Nisshoku Bldg.2-9-7, IkenohataTaito-kuJP-110-0008 TokyoTel. +81 3 5815 5606Fax +81 3 5815 5626e-mail [email protected]

MalaysiaMettler-Toledo (M) Sdn BhdBangunan Electroscon Holding, U 1-01Lot 8 Jalan Astaka U8/84Seksyen U8, Bukit JelutongMY-40150 Shah Alam SelangorPhone +60 3 78 44 58 88Fax +60 3 78 45 87 [email protected]

MexicoMettler-Toledo S.A. de C.V.Ejercito Nacional #340Col. Chapultepec MoralesDel. Miguel HidalgoMX-11570 México D.F.Tel. +52 55 1946 0900e-mail [email protected]

PolandMettler-Toledo (Poland) Sp.z.o.o.ul. Poleczki 21PL-02-822 WarszawaPhone +48 22 545 06 80Fax +48 22 545 06 88e-mail [email protected]

RussiaMettler-Toledo Vostok ZAOSretenskij Bulvar 6/1Office 6RU-101000 MoscowPhone +7 495 621 56 66Fax +7 495 621 63 53e-mail [email protected]

SingaporeMettler-Toledo (S) Pte. Ltd.Block 28Ayer Rajah Crescent #05-01SG-139959 SingaporePhone +65 6890 00 11Fax +65 6890 00 12 +65 6890 00 13e-mail [email protected]

SlovakiaMettler-Toledo s.r.o.Hattalova 12/ASK-83103 BratislavaPhone +421 2 4444 12 20-2Fax +421 2 4444 12 23e-mail [email protected]

SloveniaMettler-Toledo d.o.o.Pot heroja Trtnika 26SI-1261 Ljubljana-DobrunjePhone +386 1 530 80 50Fax +386 1 562 17 89e-mail [email protected]

South KoreaMettler-Toledo (Korea) Ltd.Yeil Building 1 & 2 F124-5, YangJe-DongSeCho-KuKR-137-130 SeoulPhone +82 2 3498 3500Fax +82 2 3498 3555e-mail [email protected]

SpainMettler-Toledo S.A.E.C/Miguel Hernández, 69-71ES-08908 L’Hospitalet de Llobregat(Barcelona)Phone +34 93 223 76 00Fax +34 93 223 76 01e-mail [email protected]

SwedenMettler-Toledo ABVirkesvägen 10Box 92161SE-12008 StockholmPhone +46 8 702 50 00Fax +46 8 642 45 62e-mail [email protected]

SwitzerlandMettler-Toledo (Schweiz) GmbHIm LangacherPostfachCH-8606 GreifenseePhone +41 44 944 45 45Fax +41 44 944 45 10e-mail [email protected]

ThailandMettler-Toledo (Thailand) Ltd.272 Soi Soonvijai 4Rama 9 Rd., BangkapiHuay KwangTH-10320 BangkokPhone +66 2 723 03 00Fax +66 2 719 64 [email protected]

USA/CanadaMettler-Toledo Ingold, Inc.36 Middlesex TurnpikeBedford, MA 01730, USAPhone +1 781 301 8800Freephone +1 800 352 8763Fax +1 781 271 0681e-mail [email protected] [email protected]

Mettler-Toledo Thornton, Inc.36 Middlesex TurnpikeBedford, MA 01730, USAPhone +1 781 301 8600Toll free +1 800 510 7873Fax +1 781 301 8701e-mail [email protected]

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ISO14001certified

ISO

www.mt.com/proDesigned, produced

and controlled according toISO 9001 / ISO14001

Documents

Operation Manual 5000TOCi Sensor - Mettler Toledo