AMI. Oxygen Analyzer Manual. Model 2001R series. AMI, Huntington Beach.

Transcription

1 Oxygen Analyzer Manual AMI Model 2001R series AMI, Huntington Beach.

2 Contents Preface 1 The AMI story 1 Caution 1 Address 1 Model 2001R Series Oxygen Analyzer 2 Introduction 2 Features: 2 Oxygen sensor: 24 Sensor Warranty: 24 Instrument Warranty: 24 Installation and Operation 25 Receiving the analyzer 25 Installation. 25 Location: 25 Precaution 25 Connect gas and power lines: 26 Interconnections: 27 Alarm connections: 28 Output connections: 28 Serial connections: 28 Sample Handling 2001R: 29 Sample Handling 2001RS (positive pressure version): 30 Sample Handling 2001RSP (ambient pressure version): 31 Sample Handling 2001RSM (positive pressure version): 32 Sample Handling 2001RSMP (ambient pressure version): 33 Sensor Installation: 34 Operation 34 General Description: 34 Security: 34 Front Panel Controls: 34 AMI Analyzer Manual Contents i

3 Output Ranges 35 View Output Range 35 Change Output Range 35 Alarm Set Points 35 View Alarm Set Points 35 Change Alarm Set Points 35 Alarm Hold Off (2001R, 2001RS or 2001RSP) 35 Alarm Silence/Sequence Time (2001RSM or 2001RSMP only) 36 Enabling/disabling sequencer channels (2001RSM or 2001RSMP only) 36 Calibration (Spanning) 36 Verify Span Factor: 38 Read the Temperature: 38 Alarm Functionality: 38 Communications 40 RS-232 communication: 40 Communication program: 41 Analyzer Section: 41 Alarms Section: 42 Data Logging 42 Advanced Calibration: 43 Maintenance and troubleshooting 44 Maintenance: 44 Periodic Calibration: 44 Sensor Replacement: 44 Sensor replacement cautions: 45 Sensor replacement procedure: 46 Bleeding a regulator 47 O rings 47 Troubleshooting 48 All oxygen applications 48 Specifications and Disclaimer 51 Specifications: 51 Disclaimer 52 Material safety data sheets (MSDS) 53 Sensor type P2, T1 53 Product Identification 53 Physical and chemical data 53 AMI Analyzer Manual Contents ii

4 Fire and explosion hazard data 54 Reactivity data 54 Health hazard data 55 Emergency and first aid procedures 56 Handling information 56 Sensor type T2 57 Product Identification 57 Physical and chemical data 57 Physical hazards 58 Health hazard data 59 Emergency and first aid procedures 59 Handling information 60 Glossary of Terms 61 Index 63 AMI Analyzer Manual Contents iii

5 Preface The AMI story The AMI series of analyzers provide the latest in high-definition oxygen analysis. The series includes trace (ppm) and percent models in several configurations. All of them share the same basic design approach, using AMI-manufactured oxygen sensors and advanced high definition electronics for noise and interference free performance. Several aspects of the design are the subject of patents, number 5,728,289 and 6,675,629; the sensors have a patent pending. AMI specializes in oxygen analysis only, so as not to dilute its expertise by trying to cover too many other fields. As a result AMI analyzers are more advanced and have more features than competitive models. Every effort is made to ensure that AMI products provide reliable, effective performance. However there are many pitfalls in achieving correct oxygen analysis, particularly at low ppm levels, and AMI stands ready to provide a complete solution to the analysis problem, from sample system design to on-site troubleshooting and problem analysis. Please feel free to call AMI for help should your results not meet your expectations. Caution Read and understand this manual fully before attempting to use the instrument. In particular understand the hazards associated with using flammable or poisonous gases, and associated with the contents of the sensor used. AMI Analyzer Manual Preface 1

6 Model 2001R Series Oxygen Analyzer Introduction The Advanced Micro Instrument Oxygen Analyzer Model 2001R Series provide the latest in high precision oxygen measurement. They are available in a variety of configurations for monitoring oxygen in percent and trace (ppm) ranges in a non-hazardous area. This manual covers software version 3.0. Features: Compact size Unique patented cell block Auto-ranging display with user-selectable output range Three customer-selected levels of security access settable via the RS232 interface. Front panel sensor access Optional air or span gas calibration, no zero gases required Virtually unaffected by hydrocarbons or other oxidizable gases High accuracy and fast response Large liquid crystal display Bi-directional serial output with simple protocol Backed by a two year warranty (excluding sensor) Standard isolated 4-20mA output Two fully adjustable alarm relay contact closures 24VDC/230VAC 5A. User selectable alarm delay-on activation User selectable pulse drivers for latching-type solenoid valves Built-in data logging with real time clock Options Sample system for positive pressure samples (2001RSM, 2001RS) Span solenoid valve (2001RS) Automatic sequencing of five inputs with programmable sequence period (2001RSM). Built in pump for drawing sample gas from atmospheric pressure areas (2001RSMP, 2001RSP) Audible alarm (2001RSM only) Option Base model with standard features With sample system With sample system and pump With sequencer With sequencer and pump Model number 2001R 2001RS 2001RSP 2001RSM 2001RSMP AMI Analyzer Manual Model 2001R Series Oxygen Analyzer 2

7 Oxygen sensor: AMI manufactures its own electrochemical sensor. This measures the concentration of oxygen in a gas stream, using an oxygen specific chemistry. It generates an output current in proportion to the amount of oxygen present, and has zero output in the absence of oxygen, thus avoiding any requirement to zero the analyzer. The cell is linear throughout its range. The span calibration may be performed using standard span gases or ambient air. Unlike competitive sensors, the AMI sensor is made using a high capacity metallic body that provides long life with about twice the active ingredients of conventional sensors, but without compromised come-down time. Sensor Warranty: The sensor is warranted to operate for a period determined by its class. If the sensor ceases to operate correctly before this time has elapsed, contact AMI for a return authorization for evaluation. If there is any evidence of defective material or workmanship the sensor will be replaced free of charge. NOTE: Any evidence of abuse or physical damage, such as a torn membrane, will void the warranty. Instrument Warranty: Any failure of material or workmanship will be repaired free of charge for a period of two years from the original purchase (shipping date) of the instrument. AMI will also pay for one way shipment (back to the user). This warranty does not cover the sensor, which is covered by its own warranty (see above). Any indication of abuse or tampering will void the warranty. AMI Analyzer Manual Model 2001R Series Oxygen Analyzer 24

8 Installation and Operation Receiving the analyzer When you receive the instrument, check the package for evidence of damage and if any is found, contact the shipper. Do not install the sensor until the analyzer is completely installed, the gas lines are plumbed and the electrical connections are all made; and sample or a suitable low oxygen level gas such as nitrogen or a low level span gas is ready to flow into it. Installation. Location: The unit is designed to be mounted in a panel in a general purpose area. It should be mounted at a suitable viewing level. Refer to the drawing (figure 1) showing the analyzer dimensions. It is not suitable for use in a hazardous area or with flammable gases. Although the unit is RFI protected, do not to mount it close to sources of electrical interference such as large transformers, motor start contactors, relays etc. Also avoid subjecting it to significant vibration. Precaution Do not install the sensor until you have connected the plumbing and power and are ready to flow zero gas. The sensor will become saturated with oxygen by exposure to air for more than a minute or so, and once it is saturated, it may take many hours or even weeks to return to a stable low reading. AMI Analyzer Manual Installation and Operation 25

9 Ø0.21 X Analyzer case outline (dashed) Cut out Front panel outline Figure 1. Outline and Cut Out Drawing Connect gas and power lines: Do not install the sensor until the gas lines have been connected and the electrical connections made. Install the unit, and connect the sample gas lines, power and appropriate alarm and output connections. Connect the sample gas line(s) to the fittings on the rear panel using the ¼ compression fittings provided, and the exhaust line to a suitable vent. Sample gas: The sample gas inlet pressure should be between 1-40psig, unless you have a P version which is capable of drawing from an ambient pressure source. If so the internal pump should not draw from more than about 1psi negative pressure; doing so will affect the reading and may damage the sensor. Span gas: 2001R: Span gas (if desired) must be provided by a user-supplied valve. 2001RS: Attach a span gas into the span inlet. The span gas pressure should be the same as the sample gas inlet pressure. 2001RSP: If using air to calibrate, simply leave the span inlet port open. If using a span gas, special precautions must be taken to make sure the gas is at the same pressure as the sample gas. Normally the best way of doing this is to allow span gas to flow out of a flowmeter into the atmosphere through a T, while allowing the pump to draw the span gas into the analyzer. As long as some gas flows out of the flowmeter, the inlet pressure of the span gas must be atmospheric. 2001RSM: If desired, connect the span gas to one of the inlet ports. Disable this port during normal use if you don t want to monitor the span gas continuously. AMI Analyzer Manual Installation and Operation 26

10 2001RSMP: Connect the span gas if desired to one of the inlet ports as above, but use the same bypass technique as described for the 2001RSP above. In this case, you will have to make sure to turn off the span gas tank when you are not using it, or you will rapidly drain it! In any case, do not rely on the internal solenoid valves to stop the span gas flow. A slight leak in the system over a period of a month or so will drain the span gas tank! Exhaust: The exhaust line may be left open, or vented to a suitable vent. If used with a scavenging system, use a large diameter pipe (for example, ½ pipe) as the input to the scavenging system, and allow the ¼ vent to terminate a little way inside this larger line without sealing it. The scavenging system will then draw in room air along with the sample, while leaving the exhaust at atmospheric pressure. Pump equipped units should have at least 1 foot of vent tubing attached to minimize pump noise. Power connections: Plug the line cord provided into the power entry module on the back panel and into a suitable 110VAC socket. (If you want to use it with 220VAC, open the little compartment on the power entry module and turn over the red insert so that 220V is showing when you close the compartment. The alarm contacts are rated at 24VDC or (nominally)250vac at 5A. Form C contacts are provided from each relay. Interconnections: RS-232 GND Rx SAMPLE OUT +15V Tx F1A ~ 250 V SAMPLE IN WARNING POSSIBLE EXPLOSION HAZARD Do not operate flammable sample without following instructions in the manual. An explosion resulting in severe personal injury or death could occur. SPAN IN ATTENTION DANGER D'EXPLOSION Ne pas offiser l'echantillon inflammable avant d'avoir pris connaissance des instructions dans le manual. Le non respect de ces instructions peut entrainer une explosion provoquant des blessures graves ou mortelles ma ISOLATED ALARM 1 ALARM GND Figure 2. Back panel of the 2001RS. Other units have different sample connections. AMI Analyzer Manual Installation and Operation 27

11 Alarm connections: The alarm connections are single pole double throw relays, i.e. Form C contacts. They may be programmed to go into alarm mode either above or below a set point, to open (the normally closed) contacts or close them, and to either latch or not latch, that is, go back out of alarm when the oxygen level returns below (or above) the set point or else wait until the operator presses the ALARM ACKNOWLEDGE (ALARM SILENCE/SEQUENCE TIME for 2001RSM) button on the front panel. The contacts can handle AC or DC voltages, and can carry up to 5A of current for a resistive load. Inductive loads such as solenoid valves should be snubbed we suggest that you connect diodes or Zener diodes or Transzorbs directly across them to absorb the inductive spike. Do not connect them across the relay terminals on the analyzer, since the resultant current loop will transmit a lot of RFI that could upset sensitive devices nearby. Output connections: This unit is equipped with an isolated 4-20mA output. It is capable of driving a 600 Ohm load and will saturate at more than 125% of the nominal full scale range. Using AMI software you can force the output to 4mA (zero output), 12mA (half scale) or 20mA (full scale), and calibrate these values so as to get the most accurate possible transfer of information to a recording or computing device. If you forget to reset them the unit will automatically return to its normal operation after ten minutes. Serial connections: An RS-232 port is provided, using a 4 pin Mini-DIN connector. This allows connection through a serial cable to a PC or similar device. The circuitry used is protected against static shocks and general abuse, but certain precautions should be taken when using this. If you are not using an AMI-supplied cable, use only a shielded cable, and make sure the shield is grounded at one end only. Don t run the cable more than about 50 feet. Make absolutely sure that the connections are correct per the diagram below. AMI can provide a program that can be used to configure the alarm settings, alarm delays, and all the other internal settings, as well as download the logged data Note: Shield MUST be connected pin Mini-DIN 9 pin D-sub Both connectors viewed from the wiring side Figure 3. RS-232 connection wiring AMI Analyzer Manual Installation and Operation 28

12 Sample Handling 2001R: Needle Valve Sample Sensor Exhaust Flow Meter Analyzer Provided by user Flow schematic - Positive pressure unit with no sample system 2001R Figure 4 Flow Schematic of the 2001R The analyzer expects to get a sample of gas at a flow rate of about 1 SCFH, exhausted to atmospheric pressure. The user has to supply appropriate sample handling equipment to achieve this. An example is shown above the user supplies a needle valve on the input to control flow, and a flowmeter on the output (exhausting to air) to monitor flow. The analyzer is not sensitive to flow changes between about 0.2SCFH and 5 SCFH, but it is sensitive to back pressure changes (changes in exhaust pressure). The flowmeter is mounted on the exhaust so that the oxygen reading is not affected by potential leaks around the flowmeter tube. Do not however use a flowmeter with an integral valve, since the back pressure generated by the valve will significantly change the oxygen reading, and may result in destroying the sensor. The front panel LED will change from green to red if the unit goes into alarm. AMI Analyzer Manual Installation and Operation 29

13 Sample Handling 2001RS (positive pressure version): Sample Span Sensor Needle Valve Cell block Flow Meter Exhaust Solenoid valve block Analyzer Flow schematic - Positive pressure unit with sample system 2001RS Figure 5 Flow Schematic of the 2001RS. This analyzer expects to see a positive inlet pressure between 1-40psig. It contains an integral needle valve and flowmeter for controlling and observing the sample flow. It also contains solenoid valves that seal off the sensor when power fails, and also that can select between the sample and a span calibration gas. The span gas should be at the same pressure as the sample (so the needle valve doesn t have to be adjusted when you select one or the other). Make sure that you turn off the span gas cylinder valve when you are not using it otherwise you may lose all the span gas if you have a tiny leak in the system somewhere. The exhaust should be vented to atmosphere or to atmospheric pressure. The oxygen reading will be affected if the pressure the sensor sees is not atmospheric. The front panel LED will change from green to red if the unit goes into alarm. If the SPAN button is held for five seconds, the span solenoid will activate and the LED will change color to blue, and flash on and off, indicating that the unit is in span mode. If it goes into alarm while in span mode, the LED will flash between red and magenta (a blue/red combination). AMI Analyzer Manual Installation and Operation 30

14 Sample Handling 2001RSP (ambient pressure version): Sample Span Sensor Needle Valve Flow Meter Cell block Bypass Flow Meter Exhaust Pump Solenoid valve block Analyzer Flow schematic - ambient pressure unit with pump and sample system 2001RSP Figure 6 Flow Schematic of the 2001RS. This analyzer expects to draw a sample from approximately ambient pressure, such as the head space of a storage tank. It draws the sample past the sensor, using a flow control valve after the sensor so as not to pull a vacuum on the sensor. It also isolates the sensor when power fails. Gas flow should be controlled to about 1 SCFH for best results, but any flow between about 0.2SCFH and 5 SCFH will work. If you connect a span gas line from a gas bottle directly to the span inlet, you will find it hard to control the flow of span gas since you will be fighting the pump when you get into the span mode. Instead we recommend the arrangement show above connect a flowmeter in parallel with the span input as shown, and adjust the span gas pressure and flow so that a little flow shows on this flowmeter when the analyzer is drawing span gas through itself. In this way, the inlet pressure of the span gas will be kept approximately the same as atmospheric pressure, and the calibration will be valid. The front panel LED will change from green to red if the unit goes into alarm. If the SPAN button is held for five seconds, the span solenoid will activate and the LED will change color to blue, and flash on and off, indicating that the unit is in span mode. If it goes into alarm while in span mode, the LED will flash between red and magenta (a blue/red combination). AMI Analyzer Manual Installation and Operation 31

15 Sample Handling 2001RSM (positive pressure version): Ch1 Ch2 Ch3 Ch4 Needle Valve Sensor Flow Meter Ch5 Orifice Cell block Exhaust Solenoid valve block Flow schematic - positive pressure sequenced unit with sample system 2001RSM Figure 7 Flow Schematic of the 2001RSM. This unit contains a manifold that allows it to sequence through up to five gas samples, with any of the samples skipped if they are not needed. It expects a positive pressure sample between 1 and 40 psig on each inlet, and the pressure must be roughly the same on each inlet since the valve is common to them all. If the source pressures vary significantly it will be necessary to provide additional external valves to equalize the flows between channels. Adjust the flow to be between 0.2 and 2 SCFH on each channel. Note that when the power is off, the sensor is sealed. If all the channels are turned off, as is the case when power is first applied, a bypass will allow flow through all the channels at once so as to remove air from the tubing prior to using the analyzer. This unit seals the sensor when power fails, although the unit should not be shipped with the sensor in it. Note that if you leave any of the inputs open, and do not disable the appropriate channel, the sensor will be exposed to high levels of oxygen when it looks at that channel. The LEDs indicate which channel is being sampled at any moment. If the analyzer goes into alarm, the appropriate LED will change color from blue to red, and the sequencer will stop so that it continues to look at that channel until the ALARM SILENCE/SEQUENCE TIME button is pressed. AMI Analyzer Manual Installation and Operation 32

16 Sample Handling 2001RSMP (ambient pressure version): Ch1 Ch2 Sensor Needle Valve Ch3 Ch4 Cell block Flow Meter Ch5 Exhaust Pump Solenoid valve block Figure 8 Flow Schematic of the 2001RSMP. This unit contains both a sequencer and pump for drawing samples from ambient pressure sources and sequencing between them. Due to the internal bypass it draws from all of the channels if the sequencer is turned off, as it is when power is first applied. Flow should be set to about 1 SCFH, and it may vary between channels if the sample tubing is different between channels. In any case it should be between 0.2 and 2 SCFH for all of them, though it does not have to be exactly the same for each. This unit seals the sensor when power fails, although the unit should not be shipped with the sensor in it. Note that if you leave any of the inputs open, and do not disable the appropriate channel, the sensor will be exposed to high levels of oxygen when it looks at that channel. The LEDs indicate which channel is being sampled at any moment. If the analyzer goes into alarm, the appropriate LED will change color from blue to red, and the sequencer will stop so that it continues to look at that channel until the ALARM SILENCE/SEQUENCE TIME button is pressed. AMI Analyzer Manual Installation and Operation 33

17 Sensor Installation: The sensor is supplied sealed in a barrier bag. When you are ready to place it in the analyzer, open the bag and rapidly place the sensor in its compartment, sensing side down. If desired, rapidly calibrate it on air, and then flow a low oxygen level gas over the sensor until it has come down to its operating range. It should take between 1 and 2 hours to get down to under 10ppm if a zero gas is flown at 1SCFH. Operation General Description: This series of analyzers is designed to be as simple to operate as possible. The analyzer displays the oxygen level in appropriate units on the LCD, automatically adjusting its sensitivity as required. Meanwhile the analog output and the alarms are set on a single (user selectable) range. For example, you can set the analog output to correspond to 0-100ppm, and the alarms to be say 40ppm and 50ppm (i.e. 40% and 50% of range), activating above set point. If the oxygen level actually is 25ppm, the display will show 25.0ppm, and the output signal will be at 25% of full scale. If the oxygen level becomes 200ppm, the display will show 200ppm, but the 4-20mA output will be saturated, and the alarms will both be activated. If you now manually change the output range to ppm, the reading will stay at 200ppm, the 4-20mAoutput will go to 20% of scale, and the alarms will de-activate, since they now correspond to 400ppm and 500ppm, i.e. still 40% and 50% of range. However if the alarms were set to latch, you would have to acknowledge them by pressing the ALARM ACKNOWLEDGE (ALARM SILENCE/SEQUENCE TIME for 2001RSM) button before they would de-activate. The unit provides a number of adjustments and controls through the front panel, and many more are available through the user interface program. The analyzer is actually made with two processors which communicate to each other over a one-wire protocol internally. The analysis unit uses a very high definition ADC to measure the oxygen signal as well as a temperature signal. Since it is so precise, it measures the full range of oxygen values with only one gain change required. This takes place at around 400ppm, and usually takes only a second or so. Security: Through the user interface, three levels of security can be set. These are: No security (all front panel controls are active), Span (only the span control and the ALARM ACKNOWLEDGE (ALARM SILENCE/SEQUENCE TIME) button are allowed to operate), and Full security (only the ALARM ACKNOWLEDGE (ALARM SILENCE/SEQUENCE TIME) button performs a function; other buttons will show settings but won t allow them to be changed). If the front panel controls don t seem to work, use the AMI User Interface to change the security settings. Front Panel Controls: The controls all work the same way. You press the function you want for a second, and let go, and the display will show the value corresponding to that function, for about 3 seconds. For example, if you press the OUTPUT RANGE button for a AMI Analyzer Manual Installation and Operation 34

18 second, the display will show the full scale output range. You can change this value (if the security setting allows) by then pressing the UP or DOWN arrow button within about three seconds. You can either press this once for a small change, or you can hold it down, in which case the number will change slowly at first, and then faster. If you overshoot your target, press the other button to go back, and the display will again start moving slowly. If you release any of the buttons, or don t press the UP or DOWN buttons for three seconds, the unit will cycle back into normal operation and store the new value. Output Ranges The output range is the range to which the 4-20mA analog output signal and the alarm settings correspond. Output ranges 0-10ppm, 0-50ppm, 0-100ppm, 0-500ppm, ppm, ppm, 0-1%, 0-5%, 0-25%. View Output Range Press the OUTPUT RANGE button on the front panel for a second, and let go. The display will show the full scale value of the output range for about three seconds, and then change back to the oxygen reading. Change Output Range Press the OUTPUT RANGE button for a second and let go. While the output range value is displayed (you have approximately three seconds), press the UP or DOWN arrow buttons to change it. The output range will change to whatever you want. Simply leave it or select another function and the range will be stored and the system updated. You will note that if this results in an alarm change, the alarms will change as soon as the unit starts showing the reading again. If the output range does not change, the security level must be set to full or span only security. In this case change the security level with the laptop and the AMI User Interface program. Alarm Set Points The alarm set points can be viewed and changed (if security allows) from the front panel. All the other alarm configuration settings can only be changed with the AMI User Interface program. View Alarm Set Points Press either of the ALARM SET POINT buttons and let go. The alarm set point will be displayed for about 3 seconds, and the then the display will revert to the oxygen reading. The set point shown relates to the current output range. If you change the output range, the alarm set point will change to a new value which is the same percentage of the new output range. For example, if the output range is 100ppm, you can set an alarm set point to be half way up, i.e. 50ppm of oxygen. If you then change the output range to 500ppm, the alarm set point will remain half way up the new range, and be displayed as 250ppm. Change Alarm Set Points Press one or the other ALARM SET POINT button for a second, and let go. While the alarm set point is showing, press either the UP or DOWN arrow button and hold it until the value is what you want. The numbers will scroll slowly at first and then speed up: if you press the other button, or release and re-press the one you are using, the number will start going slowly again. If security is set, nothing will happen. In this case use the AMI User Interface program to change the security level, or directly change the alarm set point. Alarm Hold Off (2001R, 2001RS or 2001RSP) Press the ALARM HOLD OFF button for a second and release it. The display will show the alarm hold off time in minutes, and if the analyzer was indicating an alarm, it will be turned off and held off for the period of the alarm hold off AMI Analyzer Manual Installation and Operation 35

19 time. If the alarms are programmed to latch, pressing this button will also unlatch them (and stop them from alarming again for the hold off period). If the security setting allows it, the alarm hold off time can be adjusted by pressing the UP or DOWN arrow buttons. Alarm Silence/Sequence Time (2001RSM or 2001RSMP only) Press the ALARM SILENCE/SEQUENCE TIME button and release it. The display will show either the current channel (as Ch1 or Ch2 if either of those is selected) or OFF meaning bypass, or a number which corresponds to the sequence time in minutes. You can scroll the number from 1 through 60 (minutes), and then it will scroll through Ch1 through Ch5, ending with OFF, and then rolling over to 1 (minute) cycle time again. If you select a number, the unit will scroll through all its input channels taking that number of minutes on each channel. If you select one of the Ch s (Ch1, or CH2, or so on), the unit will allow flow only from that channel. If you select OFF, the unit will draw flow from all the channels at once, but will bypass the sensor, sealing it off. When the unit is first powered on, it will come up in bypass mode. All the LED s will be on, and the pump will purge all the lines at once. The sensor will remain sealed. When enough time has passed that you think the lines now have low oxygen level gas in them, press the ALARM SILENCE/SEQUENCE TIME button and if the unit is set to sequence, it will jump to channel 1, or if not set to sequence to whatever channel it has been set at. Enabling/disabling sequencer channels (2001RSM or 2001RSMP only) While one of the channels is displayed, for example Ch1, press and hold the ALARM SILENCE/SEQUENCE TIME button until the display changes to no1. This will cause the sequencer to skip this channel during its sequencing. Press and hold the same button again to re-enable the channel. Calibration (Spanning) The model 2001R Series may be calibrated using air as the span gas, or else using a lower level gas closer to the measurement range. It is not necessary to zero the analyzer. Spanning is normally performed somewhere between once a month and once every three months, depending on the level of accuracy required. Do not attempt to span with a gas less than 20% of the range to be used, as the span errors multiply in this case and your results will be less accurate. Make sure that the flow rate of span gas is the same as that of the process gas, unless you use air as the span gas by opening the cell compartment. Adjust this with the regulator on the span gas bottle (which should be set to about 10psig), except for units with a pump: in this case, see the discussion in the 2001RSP sample handling section above. If the span gas value is such that it will cause the alarms to activate, press the ALARM ACKNOWLEDGE (ALARM SILENCE/SEQUENCE TIME) button to preemptively silence them. You may want to extend the alarm hold of time to cover the length of time you will be spanning! AIR CALIBRATION (all models) 1. Shut down the sample gas flow, either by closing an external valve, or closing the internal flow valve, or turning off all the valves in the case of the 2001RSM. 2. Open the cell cap, and blow a little compressed air under the cell. Don t use your breath as it contains less than 20.9% oxygen! 3. Press the span button momentarily, and adjust the reading up or down with the UP or DOWN arrows until it reads 20.9%. 4. Close the cell cap, and immediately flow zero or sample gas by opening the appropriate valve. 5. Units containing a pump can be allowed to draw a sample directly from the air, rather than opening the cell cap. SPAN GAS CALIBRATION Model 2001R AMI Analyzer Manual Installation and Operation 36

20 1. MAKE SURE THE REGULATOR IS BLED (see below), AND THE GAS LINES PURGED! 2. Flow sample or zero gas through the unit until it is reading a value below the span gas value. If the sensor is newly installed, allow the reading to come down to at least one tenth the span gas value; if it has been looking at a sample gas of roughly the span gas value for more than a few hours, this step is unnecessary. The idea is to make sure that any dissolved oxygen left in the sensor has had a chance to be depleted. 3. Using an external selection valve and needle valve, introduce a span gas into the cell compartment. Flow it at 1SCFH, or at any rate the same flow as the sample gas. 4. Allow the reading to stabilize. This will take only a minute or so, but you may want to leave it for five minutes to be sure. 5. Press the SPAN button, and then adjust the reading with the UP or DOWN arrow until it says the same as the marking on the tank. 6. After a few seconds, the SPAN flag will go off and the new calibration value will be stored. 7. Using the external valves, allow sample gas to flow again. SPAN GAS CALIBRATION Model 2001RS 1. Make sure that you have a span gas connected to the span inlet on the back of the unit, and that the span gas bottle valve is on and the pressure set to a reasonable value (typically 10psig). Alternatively, if this is a P version, make sure that some gas is flowing out of the bypass flowmeter per the discussion above. 2. Press and hold the SPAN button for five seconds. The span valve will be activated, and the LED on the front will flash blue. Release the button, and wait until the reading has stabilized. Then adjust the UP or DOWN buttons to make the analyzer reading match the span gas value. Once you have touched these buttons, after five seconds the span gas valve will shut off and the sample valve will turn on, and the LED will change back to green (or red if it is in alarm). 3. If not using the span gas valve feature in the 2001RS, press the span button momentarily (so that the unit shows its SPAN flag) and let it go, and then press and hold the UP or DOWN button until the reading matches the span gas value, or if using air, 20.9%. The LED will remain green during this procedure. SPAN GAS CALIBRATION Model 2001RSM 1. If using a span gas, connect it either directly to an otherwise unused input channel, or else through a three way valve into one of the input channels. Press the ALARM SILENCE/SEQUENCE TIME button and change the value shown with the UP or DOWN buttons to show that particular channel, and if the display shows nox where X is the channel number, press and hold the ALARM SILENCE/SEQUENCE TIME button until the display shows ChX where X is that particular channel number. For example, if channel 5 is only used as the span gas channel, in normal use you don t want to waste span gas so you would have it set to skip that channel by making the front panel display show no5 instead of Ch5. Now, to activate channel 5 and flow the span gas, you would press the ALARM SILENCE/SEQUENCE TIME button, run the number shown (or channel shown) to 5 (it would show no5 ), and the press and hold the ALARM SILENCE/SEQUENCE TIME button again until it shows Ch5 on the front panel. This will allow span gas to flow though channel 5 into the analyzer. The appropriate LED will be lit on the front panel. 2. Once you have persuaded the unit to flow span gas, allow the reading to stabilize and then adjust the value displayed by pressing the SPAN button, and then the UP or DOWN arrow buttons until the reading is correct. 3. Once you are satisfied with the span, press and hold the ALARM SILENCE/SEQUENCE TIME button once again until it shows no5 (continuing this example), assuming you want to skip this channel, and then press the UP or DOWN buttons to return the unit to the sequencing time value, or the continuous channel value you want it to measure. AMI Analyzer Manual Installation and Operation 37

21 Verify Span Factor: The analyzer features a Span Factor display to help you determine the state of the sensor. As the sensor ages, its output decreases gradually, and therefore the span factor has to be turned up during calibration to compensate. Press and release the UP button while the unit is showing its reading to view the span factor. The factor corresponds to the setting of a traditional ten turn span pot with a turns counter dial on it. The setting should be between 300 and 600 for a new sensor. When you calibrate the analyzer, check this value before and after the calibration. You should see that the value goes up slowly over the life of the sensor. When the value has gotten up to 1000, the sensor has reached the end of its life and should be replaced. Also, if the value suddenly jumps, it indicates that the sensor is getting close to the end of its life. Read the Temperature: Press the DOWN arrow button. The display will show the temperature of the cell block in degrees Fahrenheit. The value is limited to 25F at the lowest, and about 120F at the highest. Values outside this range will damage the sensor! If the unit is equipped with a heater, the temperature will of course be higher than ambient once the ambient temperature has dropped below 50F. Alarm Functionality: The model 2001R series has two alarms, with two associated relays. As shipped, these are set to operate as high alarms (they go into alarm if the oxygen level goes above the set point), and to close their associated relays upon alarm. Their time delay is set to zero, and they do not latch (unless specifically requested otherwise). An Alarm state is indicated by the word ALARM appearing on the display, and the status (or for 2001RSM, appropriate channel indication) LED will change color to red. Using the analyzer front panel you can change the alarm set points (if security allows), but you cannot change any of the other settings. If you want to change how they work, you must use the AMI user interface to configure them. The alarm function and the relay function are programmed independently: you can have either alarm go into alarm mode above or below set point, and you can have the relays associated with each alarm open or close upon alarm. You can set them to reset automatically, or else to latch, so that an operator has to press the ALARM ACKNOWLEDGE (or ALARM SILENCE/SEQUENCE TIME) button to reset them; you can set them to wait for a period of time before they go into alarm, and you can even set them so that one relay pulses open or closed when either alarm is triggered, while the other pulses open or close when the alarms are reset, either automatically or by the operator. Each alarm can be programmed so that an alarm occurs if the oxygen level goes above the set point, or alternatively below the set point. In either case the oxygen level will have to go a bit further the other way back for the alarm to reset in other words it has hysteresis of about 3% of range. For example, if the alarm is a high alarm set to go off at 10% on the 25% output range, when the oxygen level gets to 10% the alarm will trigger (assuming no time delay). When the oxygen level subsequently drops, it will have to drop to below 9.7% for the alarm to deactivate. A time delay may be programmed for each alarm, in minutes. The oxygen level has to be beyond the set point for the entire time of the delay, and then once the delay is up the alarm will activate. If the level goes back to the non-alarm area during the delay time, the delay will be reset and it will start again the next time the level moves into the alarm region. The alarms may also be programmed to latch, that is, once they have gone into alarm they won t drop back out until someone presses the ALARM ACKNOWLEDGE (or ALARM SILENCE/SEQUENCE TIME) button. At that point they will immediately drop out of alarm, and stay that way for the entire hold off period, or the alarm delay period, whichever is longer, even if the oxygen level is beyond the alarm set point. The ALARM ACKNOWLEDGE (or ALARM SILENCE/SEQUENCE TIME) button will immediately cancel an alarm state. AMI Analyzer Manual Installation and Operation 38

22 The final option is that the relays may be set to pulse mode. This is done by selecting a non-zero pulse time (in seconds) on the user interface. If the pulse time is set to some number of seconds, when the unit goes into alarm, alarm 1 relay will change state (to the alarm state open or closed - as programmed) for that number of seconds, and then change back again. When the unit goes out of alarm, either because the oxygen level has dropped out of the alarm region or someone has pressed the ALARM ACKNOWLEDGE (or ALARM SILENCE/SEQUENCE TIME) button, alarm 2 relay will change state to its alarm position (open or closed) for the same time, and then it will drop out. The purpose of this is to drive latching solenoid valves that require a pulse of current one way to set them, and then a reverse pulse of current to reset them. The alarm hold off period may be set by the front panel in the case of the 2001R, 2001RS or 2001RSP, or the user interface, and by default is one minute. The 2001RSM and 2001RSMP require the use of the user interface to change this value. The alarm hold off is triggered whenever the ALARM ACKNOWLEDGE (or ALARM SILENCE/SEQUENCE TIME) button is pressed, and also for the 2001RSM or 2001RSMP when the sequencer changes channels. Note that for the 2001RSM or 2001RSMP, if you leave the alarm hold off at one minute, and set the sequencer to change channels every minute, the alarms will never come on! For these two analyzers only, if the alarm does come on the sequencer will stop sequencing, and will remain on the channel which caused the alarm to trigger. Pressing the ALARM SILENCE/SEQUENCE TIME button will acknowledge the alarm, and restart the sequencer. AMI Analyzer Manual Installation and Operation 39

23 Communications RS-232 communication: Note: Shield MUST be connected pin Mini-DIN 9 pin D-sub Both connectors viewed from the wiring side Figure 9. RS-232 connection wiring The RS-232 port is located on the rear panel, and is provided as a 4 pin Mini-DIN connector. The physical connection is described in the Installation section of this manual. You can purchase made-up cables from AMI, and we recommend this as it avoids a series of possible errors. Through the RS-232 interface you can operate the analyzer from your PC, and you can set up its internal parameters to your liking. We recommend that you use the AMI communication program for reading from and setting up the analyzer. A number of the communication issues are a little touchy and the AMI program deals with them correctly. AMI Analyzer Manual Communications 40

24 Communication program: The communication program is actually two programs that run concurrently on a suitable PC. One is a low level program (called a DDE Server ) that handles the details of the communication between PC and analyzer, and the other is the user interface. Calling the user interface will automatically run the DDE server, but the latter will also automatically run by itself as a service, acting as an interface between general purpose DDE aware programs like Excel or Labview and the analyzer. However that is a more advanced topic not covered by this manual contact AMI for details if you wish to use this feature. Figure 10. User interface The program will come up, and assuming the PC is connected to the analyzer, automatically fill in all the boxes and buttons with values taken from the analyzer. You can change values by writing in the new value and pressing ENTER (on the keyboard), or by clicking the appropriate button or scroll button. The program will send the values down to the analyzer, and after a little, read the value back to make sure it took. If it didn t for some reason, the value will change back to whatever the analyzer actually has. Analyzer Section: The current oxygen reading will be shown in the Reading text box. The output range will be shown beneath it, and this can be changed by clicking on the scroll buttons. The security setting can be selected by clicking on one of the three option buttons. The first one allows no user adjustments through the front panel. Select this if you are concerned with unauthorized tampering of the analyzer. The middle one allows an operator to span the unit, but it won t let him adjust the alarms or the output range, or the ALARM SILENCE/SEQUENCE TIME time. The last one allows complete control of the analyzer through the front panel. Finally, the current cell block temperature can be read. AMI Analyzer Manual Communications 41

25 Alarms Section: First, set the desired output range. The alarms are referenced to the output range, so if you set them first, and then set the range, you will have to reset the alarms. Set the alarm set points for each alarm in the text boxes provided. The program converts the values from the analyzer (which are percent of range) into absolute values. Over-write them with the value you want, and press ENTER on the keyboard to send it down to the analyzer. For example, if you expect the oxygen values to vary between 0 and 10% of oxygen, set the Output Range to 10%. If the alarm set point should be 5% oxygen, write into one of the alarm Set Point boxes 10.0% and press Enter. Set the On Delay to the delay time you want. This is in minutes, and is independent for the two alarms. Set the relay to open or close on alarm (this is really setting whether the relay is powered or unpowered. If it opens on alarm, the relay will be unpowered, and therefore in the event of a power failure, the relay will indicate and alarm.), and the alarm to occur above or below the set point. If above the set point, the alarm will be triggered when the oxygen value becomes higher than the set point, whereas if below it will be out of alarm above the set point and in alarm below it. The remaining settings are common to both alarms. If set to Latching:, the alarms will stay triggered until someone presses the ALARM SILENCE/SEQUENCE TIME button on the analyzer. If set to non-latching, they will reset themselves when the oxygen level has gone back to the non-alarm state, above or below set point (and hysteresis) as appropriate. The Alarm Pulse Time should be set to zero if you don t want to use the pulse feature. If you do, set this to a suitable number in seconds 6 seconds is normally OK to drive a latching solenoid valve. When going into alarm, alarm relay 1 will pulse closed (or open) for six seconds, and when coming out of alarm, alarm relay 2 will pulse for six seconds. This is true no matter whether it is alarm 1 or alarm 2 that goes into alarm: but both alarm 1 and alarm 2 have to be out of alarm for the alarm relay 2 to pulse. The ALARM SILENCE/SEQUENCE TIME Time is the time in minutes that the analyzer will bypass its alarm once the ALARM SILENCE/SEQUENCE TIME button is pressed. The least value for this setting is 0, but in fact the analyzer will hold the alarms off for a minimum of ten seconds. Data Logging The program shows the current time and date, and allows you to send this to the analyzer. If the unit is not sequencing, it logs data at a rate set by the Logging Interval box. If this is set to zero, logging will be disabled. Typically this interval will be set to 1 minute. If the unit is a 2001RSM and is sequencing, it will log data at the logging interval rate. If this rate is equal to or more than the sequencing time, it will just log the data and there will be no indication of what channel is being logged. If the logging rate is less than the sequencing time (so it has a chance to store more than one data point for each channel), the first data point after the sequencer changes channel will be stored as ten times the channel number, not as a real value. Subsequent points will be stored as the peak value (rounded down) of the oxygen reading during the logging period. In other words, if the sequence time is set to five minutes, and the log time is set to one minute, the unit will first store a 10 (being ten times channel 1) and then four data points, and then a 20 (ten times channel 2) followed by four data points, and so on. Every 32 data points (including the channel reference) it stores the time and date, and the output range value. The program AMI supplies interpolates from these occasional values to produce a consistent looking graph and table of data. Non-sequenced units (2001R and 2001RS) will simply store data at the Logging interval rate. The unit is capable of storing data points, corresponding in this case to rather more than 15 days. It stores the peak oxygen level as a percentage of the current output range, with a resolution of 1% of the output range. Every 32 data points, various internal parameters including the time and date are stored as well. If the memory capacity is exceeded, the unit will overwrite the oldest data and keep on storing data in a circular fashion so that always the most recent set of data points can be retrieved. AMI Analyzer Manual Communications 42

26 You can download the stored data by pressing the Download Data button. It may take a couple of minutes to get it all, and the progress of this process is shown in a color bar, in traditional Windows style, though unlike most Windows programs the length of the bar does in fact correspond with the amount of data already retrieved. Once the data is retrieved, it can be displayed either in tabular form or else as a graph, by pressing the appropriate button. It may also be saved as an Excel compatible CSV format for subsequent analysis. In the graph display you can zoom into data by left clicking the mouse, and zoom out by right clicking. The analyzer can be left to overwrite the old data by itself, or else it can be told to start again at the beginning. It will delete all old data if told to Clear data log. Figure 11. User interface Advanced Calibration Screen Advanced Calibration: The Advanced Calibration screen allows you to calibrate the analog output, as well as see the internal gain values for the main oxygen algorithm. It does not allow you to change these latter. To calibrate the analog output, you will need to have a meter set up for measuring current. 1. Select Zero by clicking in the appropriate radio button. 2. Measure the output you actually get, and adjust the number that appears in the Adjustment box until it is correct (i.e. 4mA). You can either click on the UP or DOWN arrows, or else write a whole new value into the box, pressing Enter on the keyboard when you are done. This value is normally about Select Fullscale by clicking on that radio button. 4. Measure the output you actually get, and adjust the number that appears in the Adjustment box until the output is indeed full scale, 20mA. This number will be somewhat over 10, Select Zero again and verify that the zero is still OK, and if not adjust the adjustment value again. 6. If you have changed the zero, recheck the full scale value again. 7. Keep doing this until both ends are correct. Normally only one adjustment is needed. 8. Select the Mid scale radio button, and verify that you have 12mA. AMI Analyzer Manual Communications 43