6060 Spine Road Boulder, CO 80301 USA USA 1 800 255 6964 Europe 0161 864 6800 Worldwide 303 444 2009 Install NEMA 4X enclosure for the Sievers * InnovOx Online TOC Analyzer Introduction Purpose: To install the NEMA 4x enclosure for the Sievers InnovOx Online TOC Analyzer. Scope: This procedure describes how to install the NEMA 4X Enclosure and how to install the 2 or 5- stream InnovOx Online TOC Analyzer into the NEMA 4X Enclosure. The Enclosure is designed for use in indoor, non-hazardous locations. The Enclosure protects the InnovOx Online TOC Analyzer against falling dirt, dust, splashing and hose-directed water, and corrosion. Safety: The NEMA 4X Enclosure weighs approximately 150 lb without the Analyzer installed in it. Lift the Enclosure only using equipment designed to safely support that weight. Specifications: The NEMA 4X accessory consists of a corrosion-resistant enclosure fitted with access panels, a vortex cooler assembly, and NEMA 4X-rated pass-through fittings for fluidic and electrical connections to the Analyzer. The following drawings show the locations of the pass-throughs, vortex cooler, and related hardware. Specifications for the Enclosure are provided: Dimensions (H x W x D): Weight: Enclosure material: Ambient temperature limits: Mounting: Environment: 53.2 in. x 39.4 in. x 25.3 in. (135 cm x 100 cm x 64.3 cm) Without Analyzer or vortex cooler: 150 lb (68.0 kg) With Analyzer and vortex cooler: 235 lb (107 kg) Fiberglass-reinforced polyester 50 104 F (10 to 40 C) Wall mounted, ten 5/16 diameter fasteners Indoors, non-hazardous, not in direct sunlight Vortex cooler compressed air: Oil-free, up to 25 SCFM (0.012 m 3 s -1 ) 90 to 100 psig (620 to 689 kpa) Max. Temperature: 110 F (43 C) Vortex cooler filter element: Air line for vortex cooler: 0.0002 in. (5 μm), non-coalescing If length < 30 ft: 3/8 schedule 40 pipe If length 30 ft: 1/2 schedule 40 pipe * Sievers is a trademark of General Electric Company and may be registered in one or more countries. GE Analytical Instruments, Inc. 2010J Page 1 of 24 DIN 68640-01 Rev. B
Control (Signal) Check Standard Sample # 1 thru #5 Air to Filter Panel: #1 thru #5 Level Sensors: Check Standard Dilution Water Oxidizer Acid Reagents: Dilution Water Acid Oxidizer Left Side View GE Analytical Instruments, Inc. 2010J Page 2 of 24 DIN 68640-01 Rev.B
Filter Housing Compressed Air for Vortex Cooler AC Inlet, ½ NPT Vortex Cooler Carrier Gas Right-Side View GE Analytical Instruments, Inc. 2010J Page 3 of 24 DIN 68640-01 Rev.B
Drain for Analyzer Enclosure Drains for NEMA 4X Enclosure Waste 2X Sample #1 thru #5 Drains. From sample cup Bottom View Materials NEMA 4X Enclosure NEMA 4X Accessory Kit: (2) Mount Brackets (clamps) (6) 5/16-18 Nuts (mount clamps to instrument) (4) 10-32 x 2 L Screws (secure instrument to back panel) (4) ½ Conduit Elbows (2) 8 Flex Conduit Pieces (1) 360 of 3/8 O.D. Clear PVC Tube (drains) 3/8 NPT Tube Kit for Vortex Cooler Air Inlet Includes 2 straight pipe couplings, 1 90deg. Elbow, & 2 hose clamps. (2) Large Drain Fittings and Nuts (For ¾ O.D. Tubing) (8) Smaller Drains Fittings and Nuts (for 3/8 O.D. Tubing) (15) ¼ Drain Plugs (For sample & drain ports) GE Analytical Instruments, Inc. 2010J Page 4 of 24 DIN 68640-01 Rev.B
(5) 5/32 Drain Plugs (For filter Panel Ports) (1) Vortex Cooler with instructions and accessories (Cold Air Duct Tubing & Muffler) Items provided by user: Tools: Channel-Lock Pliers, Straight-Slot Screwdriver, Adjustable Wrench, Portable Drill and Drill Bits, Tape Measure Temporary platform for the Enclosure that is capable of safely supporting 150 lb. Hardware for mounting the Enclosure on a wall. The hardware should be selected based on sitespecific circumstances, but it must accept a 5/16 diameter fastener. Ten fasteners are recommended; in total, the mounting hardware must be able to support four times the weight of the Enclosure and Analyzer (i.e., 940 lb). Compressed air line with 3/8 NPT Male fitting for connection to filter housing Carrier gas line, 1/4 OD polyethylene or polypropylene tubing. Oil-free compressed air having a pressure from 90 to 100 psig and a temperature no greater than 110 F (43 C). The Vortex cooler requires up to 25 SCFM of compressed air. Power and signal lines in grounded metal conduit. See the InnovOx Online TOC Analyzer Operation and Maintenance Manual for details. Sample lines and drain for excess sample and Analyzer waste. See the InnovOx Online TOC Analyzer Operation and Maintenance Manual for details. Procedures A. Select a location for the NEMA 4X Enclosure and the Analyzer. B. Unpack the NEMA 4X Enclosure and prepare for installation. C. Mount the NEMA 4X Enclosure. D. Install Additional Enclosure Equipment. E. Install the InnovOx 2 or 5 Stream TOC Analyzer into the NEMA 4X Enclosure. F. Connect AC Power and Control Signals. G. Install Vortex Cooler H. Install Fail-Safe Level Sensors if so equipped. I. Install Remaining Fluidic Connections J. Finish Installation GE Analytical Instruments, Inc. 2010J Page 5 of 24 DIN 68640-01 Rev.B
A. Select a Location for the NEMA 4X Enclosure and the Analyzer 1. Place the NEMA 4X Enclosure in a non-hazardous location indoors, away from direct sunlight and exposure to extreme temperatures. The temperature must not be less than 50 F (10 C) or greater than 104 F (40 C). 2. A drain or other receptacle must be nearby to receive excess sample and acidic wastewater produced by the Analyzer. 3. The location must provide space for the Enclosure and the clearance around the Enclosure, as shown in the figures below. GE Analytical Instruments, Inc. 2010J Page 6 of 24 DIN 68640-01 Rev.B
GE Analytical Instruments, Inc. 2010J Page 7 of 24 DIN 68640-01 Rev.B
B. Unpack the NEMA 4X Enclosure and Prepare for Installation 1. Remove the NEMA 4X enclosure from its packaging. Check for damage. The enclosure will have most of the passthroughs already installed. 2. Place the NEMA 4X Enclosure on the platform that is capable of safely supporting 150 lb. This provides room for attachment of mounting brackets to the bottom of the Enclosure. (See Steps 3 and 4.) Platform GE Analytical Instruments, Inc. 2010J Page 8 of 24 DIN 68640-01 Rev.B
3. Install the 5 large stainless steel brackets, which are included in the accessory kit. One is already installed over the left side cover. The brackets slide into the enclosure between the 2 small marks on the back lip of the enclosure. Install 2 on the right side, 1 on the left side, and 2 on the bottom. 4. Secure the brackets using the plastic clips provided. The clips slide over the bracket and snap into place, keeping the brackets from slipping out of the Enclosure lip. GE Analytical Instruments, Inc. 2010J Page 9 of 24 DIN 68640-01 Rev.B
C. Mount the NEMA 4X Enclosure 1. For easier installation (optional), remove Enclosure door by pulling upper and lower pins (8 total) on hinges as far as allowed. 2. Mark the wall for location of the mounting hardware per the figure. GE Analytical Instruments, Inc. 2010J Page 10 of 24 DIN 68640-01 Rev.B
3. Use 5/16 diameter mounting hardware to affix the Enclosure to the wall. All 6 brackets must be used. The fasteners must be capable of supporting four times the weight of the Enclosure and Analyzer (i.e., 940 lbs). 4. This picture is for reference only. The application shown is in ½ drywall with appropriate fasteners. 5. The bottom brackets are attached using the center hole and a 5/16 diameter fastener. Bottom brackets are on 21.26 center. Use appropriate anchors for wall type with a 5/16 diameter fastener. GE Analytical Instruments, Inc. 2010J Page 11 of 24 DIN 68640-01 Rev.B
D. Install Additional Enclosure Equipment 1. Install the 10 NEMA 4X pass-throughs that fit into the bottom of the Enclosure. All 10 pass-throughs are in the accessory kit. An interior view of the bottom of the Enclosure is provided at the right, showing the pass-throughs installed. Any pass-through that will not have a tube must have a plug installed. Waste 2x Sample 1 thru 5 Drain. From sample block Analyzer Enclosure Drain Drain for NEMA 4X Enclosure 2. You may find it convenient to install the 3/8 OD clear tubing through the 2 or 5 NEMA 4X pass-throughs for Samples #1 thru #5 (depending on model) before installing those pass-throughs in the Enclosure. 3. If you plan to install the two tubes for the cabinet drains to the fittings for the NEMA 4X Enclosure, make sure that the tube does not extend above the fitting. See the figure on the right. 4. If you do not plan to add the two tubes to the cabinet drain fittings for the NEMA 4X Enclosure, insert 1/4 diameter plugs into the fittings. Ensure drain tubing does not extend above fitting GE Analytical Instruments, Inc. 2010J Page 12 of 24 DIN 68640-01 Rev.B
5. Install the 2 large (for 3/4 OD drain tubing) fittings in the position marked Waste in the figure shown in Step 1. E. Install the InnovOx 2-Stream TOC Analyzer into the NEMA 4X Enclosure. 1. Before installing the InnovOx 2 or 5 Stream TOC Analyzer, refer to the Operations and Maintenance manual (or the Quick-Start Guide), as well as the Installation Drawing, for proper installation procedure. GE Analytical Instruments, Inc. 2010J Page 13 of 24 DIN 68640-01 Rev.B
2. Attach one mounting bracket on the top of the Analyzer, with the bracket facing to the rear. The bracket is fastened using three 5/16-18 flange nuts provided in the accessories kit. 3. Attach a second mounting bracket on the bottom of the Analyzer, with the bracket facing the rear. This bracket also is fastened using three 5/16-18 flange nuts. GE Analytical Instruments, Inc. 2010J Page 14 of 24 DIN 68640-01 Rev.B
4. The brackets installed in Step 3 fit over the metal bars located on the rear panel inside the NEMA 4X Enclosure. Metal Bars 5. Insert the Analyzer into the Enclosure. Then lift the Analyzer onto the metal bars. Use the access panels on the right and/or left sides of the Enclosure to aid in lifting the Analyzer. AT LEAST TWO PERSONS ARE REQUIRED TO MOVE THE ANALYZER. GE Analytical Instruments, Inc. 2010J Page 15 of 24 DIN 68640-01 Rev.B
F. Connect AC Power and Control Signals. ALL ELECTRICAL INSTALLATION SHOULD BE PERFORMED BY A CERTIFIED ELECTRICIAN 1. On right side, run hard conduit to the AC Inlet connector (1/2 NPT fitting) on the right side of the NEMA 4X Enclosure. AC In 2. Install the 8 piece of conduit, and 2 90 o elbows, inside the NEMA 4X Enclosure to the Analyzer. 3. Repeat Steps 1-2 on the left side of the Enclosure to provide conduit for the Control connections. Input/Output cables will be connected to the Analyzer through this conduit. For details on making electrical connections to the Analyzer, refer to the Operations and Maintenance Manual for the InnovOx Online TOC Analyzer. Use the access panels on the sides and top of the Enclosure for access to the Analyzer s top panel and the electrical interfaces inside it. G. Install Vortex Cooler GE Analytical Instruments, Inc. 2010J Page 16 of 24 DIN 68640-01 Rev.B
1. Unpack the Vortex Cooler and refer to its Operations and Safety Instructions. Vortex Cooler 2. Attach the air inlet fittings to the Vortex Cooler as shown, using Teflon tape on all joints. Take 3/8 NPT pipe fitting with attached 90 o elbow, and screw it into fitting on Vortex Cooler. 3. Attach the 5-micron filter housing onto the elbow. Filter Housing 4. Remove spanner nut from Vortex Cooler. GE Analytical Instruments, Inc. 2010J Page 17 of 24 DIN 68640-01 Rev.B
5. Place Vortex Cooler in large hole on upper-right side of NEMA 4X Enclosure. Ensure that Vortex Cooler is oriented with the air inlet on the top. Air Inlet 6. Replace and tighten spanner nut until it is finger-tight, plus ¼ turn. 7. The properly installed Vortex Cooler assembly is displayed in the pictures on the right. Warning: When Operating, the sheet metal on the Vortex Cooler unit is hot. Do not touch. GE Analytical Instruments, Inc. 2010J Page 18 of 24 DIN 68640-01 Rev.B
8. Install muffler by adhering it to the interior of the Enclosure on the right side, approximately 8-12 below the Vortex Cooler. GE Analytical Instruments, Inc. 2010J Page 19 of 24 DIN 68640-01 Rev.B
9. Install Cold Air Duct tubing and hose clamp by pushing onto threaded fitting of Vortex Cooler. Tighten hose clamp. 10. Push the other end of the tube onto the muffler barb. 11. Push the remaining Cold Air Duct tubing onto the second muffler barb. Hose clamp GE Analytical Instruments, Inc. 2010J Page 20 of 24 DIN 68640-01 Rev.B
12. This second tube can be arranged one of two ways to distribute cold air inside the Enclosure: The tube can be left unplugged, so that the cold air exits the tube entirely at the end opposite from the muffler. If this approach is selected, ensure that the end of the tube is not pointed directly at the Analyzer. The tube can be made into a diffuser by drilling at least sixteen 1/8 diameter holes in it. Then the end of the tube is plugged as shown at the right. 13. Use the provided adhesive clips to mount the tubing to the walls of the enclosure. GE Analytical Instruments, Inc. 2010J Page 21 of 24 DIN 68640-01 Rev.B
H. Install Fail-Safe Level Sensors 1. For Analyzers fitted with the Fail-Safe Accessory: Install Level Sensor cables by pushing cables through pass-throughs on the left side of the Enclosure and the left side of the Analyzer. 2. Inside the Analyzer, attach the grounding wire on each cable to the grounding screw provided. 3. Attach float cables to proper connectors inside the Analyzer as follows: Check standard: LS1 connector Acid: LS2 connector Oxidizer: LS3 connector Dilution water: LS4 connector GE Analytical Instruments, Inc. 2010J Page 22 of 24 DIN 68640-01 Rev.B
4. Secure the 4 cables to both cable straps inside the Analyzer, and then snap straps close. I. Install Remaining Fluidic Connections 1. Refer to the Sievers InnovOx Online TOC Operation and Maintenance Manual to determine the correct fluidic connections for your Analyzer and application. 2. Extend the tube for each fluidic connection required for your Analyzer through the corresponding pass-through on the NEMA 4X Enclosure. The locations of these pass-throughs are shown in the figures on pages 2 and 3. GE Analytical Instruments, Inc. 2010J Page 23 of 24 DIN 68640-01 Rev.B
3. Plug any unused pass-through with plugs supplied in the accessories kit. For example, if the Analyzer will only monitor one sample stream, plug the sample #2 thru #5 inlets on the left side of the Analyzer and the Sample #2 thru #5 drains on the bottom. 4. If the Analyzer is not fitted with 2 to 5 Filter Panels, plug the unused Air-to-Filter Panel pass-through(s) of the left side of the Enclosure. 5. If the Analyzer is not fitted with the Fail- Safe Accessory, plug the pass-throughs for the Level Sensors on the left side of the Enclosure. J. Finish Installation 1. On the exterior of the Enclosure, tighten each pass-through around the tube (or cable) that is inserted in it. Finger-tighten the outer nut around the tube/cable. 2. Plug any pass-through on the Enclosure that does not have a tube or cable in it. 3. Place all of the drain tubes into their appropriate drains or receptacles. 4. Remove plastic around the NEMA 4X Enclosure. 5. Dispose of removed materials according to local regulations. 6. Complete the installation procedures in the Sievers InnovOx Online TOC Analyzer Operation and Maintenance Manual. 7. If a Filter Panel is used with the Analyzer, complete the relevant installation procedures. Refer to the GE InnovOx Filter Panel Operation and Maintenance Manual. 8. Turn on the compressed air to the Vortex Cooler. 9. Follow the Start-Up procedure in the Sievers InnovOx Online TOC Analyzer Operation and Maintenance Manual. 10. Close and secure the front door and all access panels on the NEMA 4X Enclosure. GE Analytical Instruments, Inc. 2010J Page 24 of 24 DIN 68640-01 Rev.B