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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 5stream 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):
53.2 in. x 39.4 in. x 25.3 in. (135 cm x 100 cm x 64.3 cm)
Weight:
Without Analyzer or vortex cooler: 150 lb (68.0 kg)
With Analyzer and vortex cooler: 235 lb (107 kg)
Enclosure material:
Fiberglass-reinforced polyester
Ambient temperature limits:
50 – 104 °F (10 to 40 °C)
Mounting:
Wall mounted, ten 5/16” diameter fasteners
Environment:
Indoors, non-hazardous, not in direct sunlight
Vortex cooler compressed air:
Oil-free, up to 25 SCFM (0.012 m3 s-1)
90 to 100 psig (620 to 689 kPa)
Max. Temperature: 110 °F (43 °C)
Vortex cooler filter element:
0.0002 in. (5 μm), non-coalescing
Air line for vortex cooler:
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
InnovOx OL NEMA 4X
Control (Signal)
Check
Standard
Sample # 1 thru #5
Air to Filter Panel:
#1 thru #5
Reagents:
Dilution Water
Acid
Oxidizer
Level Sensors:
Check Standard
Dilution Water
Oxidizer
Acid
Left Side View
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Page 2 of 24
DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
Compressed Air for Vortex Cooler
Filter Housing
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
InnovOx OL NEMA 4X
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)
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Page 4 of 24
DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
•
•
(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
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Page 5 of 24
DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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Page 7 of 24
DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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
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Page 8 of 24
DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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.
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Page 10 of 24
DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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.
Ensure drain
tubing does not
extend above
fitting
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.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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
90o 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
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
1.
Unpack the Vortex Cooler and refer to its
Operations and Safety Instructions.
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 90o elbow, and screw it into
fitting on Vortex Cooler.
3.
Attach the 5-micron filter housing onto
the elbow.
4.
Vortex Cooler
Filter Housing
Remove spanner nut from Vortex Cooler.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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.
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.
Air Inlet
Warning: When Operating, the sheet
metal on the Vortex Cooler unit is
hot. Do not touch.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
8.
Install muffler by adhering it to the
interior of the Enclosure on the right side,
approximately 8-12” below the Vortex
Cooler.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X
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 FailSafe 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.
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DIN 68640-01 Rev.B
InnovOx OL NEMA 4X