Manual GC 5000 BTX Version 5 -11- 2010 - o Titel GC...Operating Manual GC 5000 BTX; Version 5 –...

Operating ManualGas chromatograph – GC 5000 BTX

address of manufacturer:AMA Instruments GmbH Soeflinger Straße 10089077 Ulm, GermanyTel +49 731 933-2100Fax +49 731 933-2110

imprint:Operating Manual GC 5000 BTX Version 5.0; EnglishDate: 11/2010

Operating Manual GC 5000 BTX; Version 5 – 11/2010 1

Table of Contents Page 1.0 Information for the owner …………………………………………………........... 5 1.1 How to use the manual ……………………………………………………………… 5 1.2 Specific normal operation …………………………………………………………… 5 1.3 Delivery information …………………………………………………………………. 6 1.4 Standard and regulations …………………………………………………………… 7 1.5 Declaration of conformity …………………………………………………………… 7 1.6 Copyright ……………………………………………………………………………… 8 1.7 Service address ……………………………………………………………………… 8 2.0 Hazard Information ………………………………………………………………… 9 2.1 General hazard information ………………………………………………………… 9 2.2 Responsibility of the operator ………………………………………………………. 10 3.0 Product description - technical specifications ……………………………….. 11 3.1 Normal use of GC 5000 BTX ……………………………………………………….. 11 3.2 Hardware description ……………………………………………………………….. 12 3.3 Description of GC components .…………………………….……………………… 14 3.3.1 System control and watchdog.…………………………………………………….. 14 3.3.2 GC oven ………………..…………………………………………………………….. 14 3.3.3 Columns………………………………………………………………………... ……. 14 3.3.4 Detector……………………………………………………………………………….. 14 3.3.5 Setup of parameters….……………………………………………………………… 14 3.4 Technical data (GC 5000 BTX)..…………………………………………………... 15 3.5 Options……………………………………………………………………………….. 17 3.5.1 Calibration gas selector (optional)………………………………………………….. 17 3.5.2 Ozone precursor monitoring system (optional) ...………………..……..………… 17 3.5.3 Optional modules……………………………………. ….…………..………………. 18 3.5.3.1 Dilution module DIM 200……………………………………. ….…………..………. 18 3.5.3.2 Sample stream selector SSM 600…………………………. ….…………..………. 19 4.0 Installation …………………………………………………………………………… 21 4.1 Safety instructions…………………………………………………………………… 21 4.2 Installation condition ………………………………………………………………… 22 4.3 Gas connections …………………………………………………………………….. 22 4.4 Electrical connections ………………………………………………………………. 23 5.0 Start up and shut down ..……..…………………………………………………… 24 5.1 Safety instructions …………………………………………………………………… 24 5.2 Start up instructions …………………………………………………………………. 25 5.3 Decommissioning…….. …………………………………………………………….. 27 6.0 Setting up the GC 5000 Software ……………..…………………………………. 28 6.1 Status screen ……………………………………..………………………..………… 28 6.2 How to unlock – password protection ………….………………………………….. 30 6.3 How to select operation modes………………….…………………………………. 31 6.4 How to select master modes .……………………………………………………… 31 6.5 How to select communication parameters… …………………………………….. 32 6.5.1 Analog outputs configuration……………………………………………..…………. 32 6.5.2 Alarm configuration…………………………………………………..…..………….. 34 6.5.3 Gesytec specifications………………………………………………..…..………….. 35 6.5.4 Modifying parameters under “Gesytec specifications”..………………………….. 35


Page 7.0 Starting operation …..…………………………………………………………… 38 7.1 How to start measurement………………………………………………………….. 38 7.2 How to adjust the retention time windows………………………………………… 41 7.3 How to zoom / zoom out the chromatogram……………………………………… 45 7.4 How to optimize integration parameters…………………………………………... 47 8.0 Using LCD display and buttons on the front panel …………..….………… 48 9.0 Calibrating and validating ……………………………………………………… 51 9.1 Calibration……………………..……………………………………………………... 51 9.1.1 Calibration intervals..……..………………………………………………….………. 51 9.2 How to enter the data of calibration gas concentrations..……………….…….. 52 9.2.1 Enter data - without a calibration gas module..…….………………………..…… 52 9.2.2 How to disable concentration levels ……………….……………………………… 52 9.2.3 Enter data - with a calibration gas module .……………………………………… 53 9.3 How to start a calibration…………………………….……………………………... 55 9.3.1 Calibration of one level………………………………………………………………. 55 9.3.2 Calibration of sequence (without calibration module or cal. valves) .………… 56 9.4 Auto-calibration………………………………………………………………………. 57 9.5 Validation………………………..……………………………………………………. 58 9.5.1 Principle of validation……..…………………………………………………………. 58 9.5.2 Types of validation……………………………….………………………………….. 58 9.5.3 How to start validation……………………………….………………………………. 59 10.0 Functional description ……………………………………………………………. 64 10.1 Measuring principle …………………………………………………………………. 64 10.2 Definition of the program step …………………………………………………….. 65 10.3 Program example …………………………………………………………………… 67 11.0 Software reference ………………………..……………………………………… 68 11.1 Basic software design ..…………………………………………………………...... 68 11.1.1 Software architecture ..…………………………………………………………....... 68 11.1.2 Configuration files …………………………………………………………………… 68 11.1.3 Main window: Program……………………………………………………………… 69 11.1.4 Menu items…………………………………………………………………………… 71 11.2 Unlock…………………………………………………………………………………. 72 11.3 Parameters……………………………………………………………………………73 11.3.1 Change password……………………………………………………………………. 73 11.3.2 Operation mode……………………………………………………………………… 73 11.3.3 Remote control……………………………………………………………………….. 74 11.3.4 Master mode………………………………………………………………………… 77 11.3.5 Method………………………………………………………………………………… 77 11.3.6 Analysis……………………………………………………………………………… 78 11.3.7 GC Oven……………………………………………………………………………. 79 11.3.8 Calibration…………………………………………………………………………… 81 11.3.9 Validation set up…………………………………………………………………… 84


Page 11.0 Software reference continuing 11.3.10 Analog output configuration………………………………………………………… 85 11.3.11 Alarm configuration…………………………………………………..…..………….. 86 11.3.12 CP Analysis…………………………………………………………………………… 87 11.3.13 CP File Editor……………….……………………………………………………...... 88 11.3.14 Module setup………………..……………………………………………………...... 97 11.4 Program steps……………………………………………………………………….. 98 11.4.1 Standard BTX …………………………………………………………………………98 11.4.2 BTX with stripper Column ………………………………………………………….. 101 11.5 View…………………………..……………………………………………………….. 104 11.6 Run calibration (manual and auto-calibration)……………………………………. 107 11.7 Run validation ……………………………………………………………………….. 109 11.8 Help functions …………….………………………………………………………… 110 11.8.1 Remote support….………….………………………………………………………. 110 11.8.2 About (current Software Version)………………………………………………….. 110 12.0 Miscellaneous procedures ……………………………………………………… 111 12.1 Programming and editing values ………………………………………………….. 111 12.2 Programming GC oven parameters …………………………………………….. 112 12.2.1 How to display the running temperature program …………..…………………… 112 12.2.2 Select the parameters for the running temperature program ………………….. 113 12.3 Start and stop ……………………………………………………………………… 114 12.4 Subsequent data processing………………..……………………………………… 116 13.0 Maintenance ………………………………………………………………………. 119 13.1 Security instructions ………………………………………………………………… 119 13.2 Maintenance schedule ……………………………………………………………… 120 13.3 Maintenance work ……………………………………………………………….. 121 13.3.1 Exchange the enrichment tube …………………………………………………….. 121 13.3.2 Maintenance of the pump ………………………………………………………….. 122 13.3.3 Exchange the input filter of the MFC ……………………………………………… 122 13.3.4 Exchange or repair the capillary column ………………………………............... 123 13.3.5 Adjust the detector signal ………………………………………………………….. 125 13.3.6 Check the glow plug ………………………………………………………………… 125 13.3.7 Check the thermocouples ………………………………………………………….. 126 13.3.8 Check the heating units of detector and valve oven ……………………………. 126 13.3.9 Exchange of the PID lamp ………………………………………………............... 127 13.3.10 Clean the PID lamp window ………………………………….……………………. 128 13.3.11 Exchange the rotor of the rotary valve …………………………………………… 128 13.3.12 Exchange the GC oven motor …………………………………………………….. 130 13.3.13 Exchange the back panel fan ……………………………………………..………. 130 13.3.14 Exchange the Peltier cooler fan …………………………………………………… 131 13.3.15 FID maintenance …………………………………………………………............... 131 14.0 Troubleshooting …………………………………………………………………. 132 14.1 General faults ……………………………………………………………………… 132 14.2 Alarm messages …………………………………………………………………….. 134 14.3 Warning messages………………………………………………………………… 136 14.4 Error messages ..……………………………………………………………………. 139 15.0 Spare parts list ……………………………………………………………………. 140


Page 16.0 Warranty ……………………………………………………………………………. 140 17.0 GESYTEC-II protocol ……………………………………………………………. 141 17.1 Telegram definitions…………………………………………………………………. 142 17.2 Status request MZ…………………………………………………………………… 142 17.3 Status response ZM…………………………………………………………………. 142 17.4 Data request DA ..…………………………………………………………………… 143 17.5 Data response AD…………………………………………………………………… 144 17.6 Control command ST ………………………………………………………………. 144 17.7 Control response TS ………………………………………………………………... 146 17.8 Appendix ………..……………………………………………………………………. 146

18.0 Digital I/O ……………………………………………………………………………. 148 18.1 General ………..……………………………………………………………………. 148 18.2 Digital outputs…..……………………………………………………………………. 149 18.3 Digital inputs…..……………………………………………………………………. 150


1 Information for the owner

1.1 How to use the manual

Caution!

Please read this manual carefully before starting with operation.

The manual will provide you with information on using, installing, operating

and maintaining this unit. It ensures proper functioning and helps you to

operate the device more easily and efficiently.

Symbols:

Caution!

Pay particular attention to all kind of warnings and notes. Information of this

type is set apart from the rest of the text and specially identified by

appropriate symbols and pictograms

1.2 Specified normal operation

Before the system left the factory, it has been inspected and found to be in

perfect condition as regards safety. To ensure a safe and problem-free

operation, the product should only be used in the manner described by the

manufacturer. In addition, proper transportation, storage and initial

installation are vital to ensure a correct and safe operation as well.

This manual provides the information you will need to use the described

product in the proper manner for which it is intended. This manual includes

several safety information (including warnings). The knowledge of this

information is essential for hazard-free installation and operation as well as

maintenance.

Therefore the manual refers to technically qualified personnel especially

trained and authorized for maintenance and service of analyzer and

monitoring devices. Moreover they possess the knowledge of correct

interpretation of the safety information and warnings provided in this

manual. This ensures as well to put it properly into practice.

Note

The GC 5000 is configured and calibrated ex factory with your required

application. In particular you intend to use the analyzer for new applications,

we recommend you to contact your local supplier to discuss the application

in question. (See chapter 2.2 and 3.1as well)


1.3 Delivery information

When you receive the shipment, please check the following:

1. The packaging is not damaged.

2. Both indicators labels which are fixed on the package should display

the white color as a sign for proper transportation.

The package of the analyzer is posted with one so-called

“shockwatch” indicator label and one “tilt watch” indicator label. Both

labels change their color from white to red in case of improper

handling by the forwarder regarding tilts and shocks.

Note!

In case one of the indicator labels is red or both, note it on bill of lading,

inspect the shipment for damage and inform AMA Instruments within 10

days after arrival at latest.

The scope of delivery is corresponding to the relevant purchase contract

and is shown on the documents enclosed with the shipment:

3. Open the packaging and check whether the shipment is complete.

4. Check the serial number on the type plate with the serial number

specified in the shipping documents.

5. The operating manual is delivered on CD-ROM and recorded on the PC

of the analyzer as well.

Note!

Do not throw the original packaging away: A saver shipment is guaranteed

while using the original purpose-made packaging (it contains foamed

plastic inserts which are adapted to the size of the analyzer). Therefore we

recommend the storage of the original packaging.

6. First visual check-up of the analyzer:

When unpacking the system, remove the cover and have a closer look

to the interior of the analyzer. The following checklist may be of help:

All parts are fixed

Check additionally if the plug in card and the riser card are fixed

properly (optional installation)

Remove the cover of the GC oven and make a sight check of the

column

In case the column is broken, follow the instruction of chapter 13.3.4

- how to cut and repair a capillary column in the right way.


1.4 Standards and regulations

As far as possible the specifications and manufacture of this unit are based

on the harmonized European standards.

If this product is used outside the area of validity of these standards and

regulations, the standards and regulations valid in the owner’s country

should be observed.

1.5 Declaration of conformity

Our product GC 5000 BTX

is manufactured in compliance with the following standard(s) or documents:

Low-Voltage Equipment Directive 2006/95/EG

EMC Directive 2004/108/EG

Harmonized standards EN 61326 and EN 61010

In accordance with the named above EC directives, the EC Declarations of

Conformity are kept available for the relevant Authorities by

AMA Instruments GmbH

Soeflinger Strasse 100

D-89077 Ulm / Germany

If this product is used outside the European Union, the standards and

regulations valid in the owner’s country must be observed.


1.6 Copyright The reproduction, transmission or use of this document or its contents is

not permitted without express written authority. Technical data are subject

to change. All rights are reserved by AMA Instruments GmbH, Ulm,

Germany.

1.7 Service address

If you require further information, which are not treated in sufficient depth in

this document or in case of malfunction, please contact your local supplier.

The responsible service engineer will provide you with the required

information.

In case of malfunction, it is recommended to have the following information

on hand:

• Detailed description of the failure

• Serial number of the system (on the back side of the analyzer)

Note!

In case of a repair, we would welcome your detailed information about the

failure in order to assure an efficient handling for a fast return shipment of

your system.

Note

For a saver shipment we recommend the use of the original packaging of

the analyzer which is purpose-made. (It contains foamed plastic inserts

which are adapted to the size of the analyzer.). For proper shipment the

system should be transported on a pallet.


2 Hazard information

2.1 General hazard information

Please observe the following notes to safeguard against damage to the

system described as well as to any systems which may be connected to it.

Safety information and warnings are given particular emphasis in this

manual by means of various symbol terms defined below. They apply to

both, users and service / electrical technicians. They intend to help

preventing dangers to life and health as well as preventing damages to

properties. These notes are also marked by warning symbols which reflect

the meaning of the accompanying text. Within the context of this manual

and information on the product itself, the terms used are defined as follows:

Danger!

This means that death or severe injury or considerable damage to property

will result if the corresponding precautions are not taken.

Warning!

This means that death or severe injury or considerable damage to property

could occur if the corresponding precautions are not taken.

Caution!

This means that damages to property may result if the corresponding

precautions are not taken.

Note

Provides important information about the product, about using it or about a

corresponding part of the manual to which special attention has to be

shown.


2.2 Responsibility of the operator

The analyzer described can only be used for applications which are

described in chapter 3.1. For operation of the system, the technical data

described in chapter 3.4 must be observed.

The analyzer described in this manual has been designed, manufactured,

inspected and documented in compliance with the relevant safety

standards. The design of the GC 5000 BTX ensures a safe operation. If the

operator follows the handling requirements and observes safety instructions

which are described for installation, operation and maintenance, then the

system will be not a source of danger to individual health and safety or to

property.

Warning!

In case you open the unit, certain parts which apply hazardous voltage

become accessible. Only qualified and accredited technicians in the field of

electricity are permitted to have access.

Only qualified and trained personnel with a thorough knowledge of all

sources of danger are permitted to have access to this system. Regarding

the safety information in this manual, qualified personnel is defined as

follows:

• The operating personnel – They are trained in operating the system

and observing its safety requirements. As well they are familiar with the

operation-related content of this manual. This means they are able to

fully understand the English written safety instructions.

• The commissioning or maintenance personnel – They are authorized to

install, operate, maintain and repair this kind of systems and electrical

circuits in accordance with accepted technical safety standards. They

possess the authorization and appropriate training to putting into

operation, maintain and repair this system. Furthermore they are able

to fully understand the English written safety instructions and

maintenance requirements as well.


3 Product description - technical specifications 3.1 Normal use of GC 5000 BTX

The AMA GC 5000 BTX has been developed for the continuous monitoring

of emission and immission levels of organic compounds in ambient air and

gas streams in the range of C4 – C12. The instrument is characterized by its

compact design and its outstanding detection sensitivity in the ppt- range.

The analyzer is type approved according to DIN EN 14662-3 (August 2005)

and can be used for the legally obliged monitoring of benzene in ambient

air according to the guideline 2000/69/EC of the European parliament and

the council from November 16th 2000.

At the same time often concentrations of other aromatic hydrocarbons are

monitored as well.

According to the EU guideline 2002/3/EC from February 12th 2002, the VDI

guideline 2100 and the guidelines of the Technical Assistance Document

EPA/600-R-98/161 of the American environmental protection agency EPA

from September 30th 1998 the analysis system is also suitable for the

continuous monitoring of ozone precursors in the range of C4-C12.

A system for continuous monitoring of the complete range of ozone

precursor from C2-C12 can be configured by combining the GC 5000 BTX

and the GC 5000 VOC.

General range of applications:

• Ambient air monitoring, immissions and emissions control

• Aromatic hydrocarbons (BTEX, styrene, trimethylbenzene, ethyltoluene)

• Aliphatic hydrocarbons (1,3-butadiene, methylcyclopentane, methylhexane)

• Chlorinated hydrocarbons (vinyl chloride, tri-chloroethene, tetra-

chloroethene)

The GC 5000 BTX analyzer is configured and calibrated ex factory with

your required standard application. This means that the equipment of the

system is adapted specifically to the required measuring task.

Application ex factory


3.2 Hardware description - Overview

The GC 5000 BTX analyzer is constructed as a 19” plug in case. All

necessary parts are integrated as there are

• electronic control unit,

• PC, heater controller,

• gas regulation etc. and

• optional equipment as output requirements, calibration gas selector or

controller for external devices as permeation modules etc.

A 10” monitor is available optionally as well. Otherwise a monitor can be

connected to the external VGA interface.

Fig. 1: Front view of the GC 5000 Analyzer


Fig. 2: Rear view

Fig. 3: Gas regulation inside the analyzer


3. 3 Description of GC components

3.3.1 System control and watchdog

System control is realized via a built-in PC board with Windows XP and the

AMA control software.

Note

The GC 5000 features a hardware watchdog. In case of a software crash

or an operating system crash, the watchdog resets the internal PC. Then

the operating system and the AMA control software are started again

automatically and the GC 5000 is operating properly again. The

automated restart of the analyzer helps your service personnel: No extra

visits to the monitoring station are necessary.

3.3.2 GC oven

The GC module features a three step temperature program. It enables to

work with high end temperatures without having long cooling down-times as

construction and used materials of the GC components are characterized

by preventing from thermal inertia.

The dimensions of the oven are 21cm * 21cm * 8cm which makes app.

3500 cm3. The geometry of the oven allows the use of columns with their

own cages.

The maximum linear heating rate for the range between 40 -200°C is

25°C/min, adjustable in steps of 1°C/min.

3.3.3 Columns

The dimensions of the oven allow the use of commercial capillary columns.

This helps to exchange a column in a few minutes.

The GC can be equipped with capillary columns with an internal diameter of

0.32mm, 0.45mm or 0.53 mm and up to 60m length. For standard

applications use a 0.32mm column.

3.3.4 Detector

The standard detector is a FID (Flame Ionization Detector) or a PID (Photo

Ionization Detector). The output of the detector is an analog signal of 0-5 V.

The signal is digitized and analyzed by chromatography software.

3.3.5 Setup of parameters

The control software allows to enter and to modify all analysis parameters.

Unauthorized access is avoided due to password protection.


3.4 Technical data GC 5000 BTX

General

Case 19” plug-in case

Height 6 height units

Depth 600 mm

Weight approx. 40 kg

Ambient temperature 5°C to 35°C (if temp. exceeds this range, air conditioning is required)

Humidity 5% to 95% relative humidity, non-condensing

EMC CE-marking, conformity with EMC guideline 2004/108/EG

Instrument supply

Voltage 220-240 VAC; 110-120 VAC (optional)

Line frequency 50 to 60 Hz

Power consumption max. 800 W

Carrier gas Nitrogen GC grade (5.0 = 99.999%), 3 bar

Supply gases (for FID

only)

Combustion air, GC grade 2 bar;

H2 , GC grade, 2 bar

Gas connections 1/8” Swagelok

Pressure control Integrated pressure regulators, electronic readout of carrier gas

pressure, manometers for indication of supply gas pressures (for

FID only)

Flow control MFC for precise flow control of hydrogen supply (for FID only)

Sampling

Sampling Maintenance-free membrane pump for automated air sampling

Volume measurement Mass flow controller with flow sensor for precise measurement and

control of sample volume irrespective of fluctuations in atmospheric

pressure and temperature

Sampling time 0-99 min (adjustable)

Flow rate MFC, 5-50 sccm/min (adjustable)

Sample volume Typical 200-800 sccm (adjustable)

MFC inlet filter Sintered metal filter, stainless steel 2µm

Enrichment

Enrichment module Single-stage enrichment module with integrated thermal desorption

unit for pre-concentration of organic components ≥ C4

Enrichment temperature Typical 30°C (adjustable)

Desorption temperature max. 350°C (adjustable)

Heating-up rate Up to 40°C/s providing high-speed sample introduction, which

results in optimized peak separation

Valve oven

Oven liner Stainless steel

Internal dimensions H 70 mm x D 80 mm x W 210 mm

Heated valve block Temperature controlled, adjustable from 40-150°C

Sample valve 6-port VALCO valve, electrically actuated


GC oven

Oven liner Stainless steel

Internal dimensions H 55 mm x W210 mm x D 210 mm

Analytical column Fused silica capillary, length up to 60 m

Heating Forced air

Temperature range 40°C to 210 °C

Temperature control Closed loop PID, set point resolution 1°C

Temperature program 3 linear heating ramps, 4 isothermal holds

Heating rate 1°C/min to 25°C/min, set point resolution 1°C/min

Oven cooling Fast cooling down due to forced air cooling

Computer

specifications

Hardware Intel Atom 1.6GHz dual core, 1 GB RAM, 2,5” hard disk

Communication ports 2x Ethernet, RS232 / RS 485, 4x USB, PS2, VGA

Protocols GESYTEC II, other protocols on request

Operating system Windows XP Professional

Protection Password protection

Watchdog Hardware watchdog for an automated restart of the analyzer in case

of a software crash or an operating system crash.

Detector (select one

type)

FID – Flame Ionization

Detector

- Stable signal output due to temperature controlled detector block

- Make-up gas connection provides enhanced detection sensitivity

- Amplifier output 0-5 VDC

- Requires H2 and combustion air supply

PID – Photo Ionization

Detector

- Electrode-less, radio frequency excited UC lamp provides

increased UV intensity and extended lifetime of lamp

Options for GC 5000

Display 10” Touch screen

Communication Various I/O modules, analog outputs and digital I/O

Calibration Calibration gas selector (Sample, Cal1, Cal 2)

Accessories Developed for optimized connection with GC 5000

Sample stream selector SSM 600, Art.-No. 00001327

Dilution module DIM 200, Art.-No. 00000980

Combustion air supply

for FID

Dry-running compressor with exchangeable charcoal filter;

Art-No. 00000256


3.5 Options

3.5.1 Calibration gas selector (optional)

The AMA GC 5000 BTX can be equipped with two different calibration gas

supplies.

1. Calibration gas generator:

The analyzer is equipped with a communication interface to external

gas generators.

2. Calibration gas cylinders:

Fig. 4: Gas flow scheme of the calibration gas selector

Optionally the analyzer can be equipped with a valve array for the selection

of different sources of sampling. The array consists of 3 valves and can be

used for one ambient source and two calibration sources. The needle

valves of the calibration gas cylinders have to be adjusted to 70ml/min or

more.

3.5.2 Ozone precursor monitoring system (optional)

For the on-line monitoring of hydrocarbons C2-C11 (ozone precursor) in

one system, the AMA BTX analyzer can be synchronized with a AMA VOC

analyzer.

You have to select “Master mode on” in the BTX analyzer parameters and

“Slave mode on” in the VOC analyzer parameters. Then each cycle and

each calibration is started by the BTX analyzer.


3.5.3 Optional Modules

3.5.3.1Dilution module – DIM 200

The DIM 200 provides calibration gas at specified concentration levels for

precise calibration of monitoring devices. The calibration gas is generated

by diluting a source calibration gas with zero gas (e.g. nitrogen or purified

air).

The DIM 200 can be controlled manually or remotely via bus

communication by any AMA monitoring device or via digital I/O’s. This

allows for periodic validation and/or calibration of monitoring devices even

while running in unattended operation mode.

If the DIM 200 is controlled remotely by any AMA GC system, also setup of

the module is fully integrated into the analyzer software.

Technical data DIM 200:

General



Depth 400 mm

Weight 8 kg

Mounting designed for cabinet / rack mounting




Instrument supply

Voltage 100-240 VAC



Supply gases Zero air (purified air or N2) 3 bar;

Source calibration gas, 3 bar

Sample gas

Supply connections 1/8” Bulkhead union for calibration gas and sample in/out

1/4” bulkhead union for zero gas and bypass

Gas flow control

Source calibration gas Mass flow controller, 2 to 100 sccm/min, accuracy +/- 0.5% of

reading

Zero gas Mass flow controller, 100 to 5000 sccm/min, accuracy +/- 0.5% of

reading

Dilution range 1 to 2500

Concentration levels Up to 5 levels (manual operation or remote control via digital I/O’s)

Up to 20 levels (remote control by AMA monitoring devices)

Gas flow concentrations Certification of the DIM 200 optionally available by factory-set

correction of flow rates determined by an independent and

accredited body for gas certification

Supplied gases Digitally controlled solenoid valves to supply either sample gas, zero

gas or calibration gas at sample out port

Microprocessor controlled gas calibration

Automated calibration of monitoring devices


Operation

Module set-up Menu-driven user interface for manual set-up and operation

DIM 200 control software for convenient module set-up optionally

available

Display Large and back-lighted LCD display to indicate module status level,

names of analytes, concentrations and dilution factors

Data entry Splash-proof membrane keypad

Operation modes Manual operation, remote control via digital I/O’s, remote control by

any AMA monitoring device via bus communication

Communication

Communication ports 2x RS-485, 25 pin SUB-D connector for digital I/O’s

Digital I/O’s Digital inputs for module control

Digital outputs for indication of selected concentration levels, zero

gas supply, sample gas supply, error status, equilibration mode and

service mode

Options

Control software DIM 200 control software for convenient module set-up

Certification Certification of DIM 200 (includes factory-set correction of flow

rates)

Order Number

Dilution module DIM 200, Art.-No. 00000980

3.5.3.2 Sample stream selector – SSM 600

The SSM 600 is a microprocessor controlled sample stream selector for

monitoring of up to 6 gas streams. A menu-driven user interface allows for

easy configuration of the SSM 600.

The SSM 600 can be controlled manually or remotely. Remote control can

be performed via digital I/O’s by any external control unit or via bus

communication by any AMA monitoring device. This allows for automated

selection of sample streams while running in unattended operation mode.

If the SSM 600 is controlled remotely by any AMA GC system, setup of the

module is fully integrated into the analyzer software. All settings can be

saved and loaded together with the analytical method. For effective purging

of the sample line a low maintenance membrane pump is optionally

available.


Technical data SSM 600:

General



Depth 400 mm

Weight 8 kg

Mounting designed for cabinet / rack mounting




Instrument supply

Voltage 100-240 VAC without pump; 220-240VAC with pump (110-120 VAC

optional)



Gas connections 1/8” bulkhead union, stainless steel

Operation

Module set-up Menu-driven user interface for convenient configuration

Display Large and back-lighted LCD display to indicate number of selected

sample stream and module status

Data entry Splash-proof membrane keypad

Operation modes Manual operation, remote control via digital I/O’s, remote control by

any AMA monitoring device via bus communication

No. of sample streams 1to 6 sample streams

Communication

Communication ports 2x RS- 485, 25 pin SUB-D connector for digital I/O’s

Digital I/O’s Digital inputs for module control

Digital outputs for indication of selected sample stream, error

status, equilibration mode and service mode

Options

Low maintenance membrane pump for sample line purging

(recommended for sample lines at a length of 5 meters or mores)

Order Number

Sample stream selector SSM 600, Art.-No. 00001327


4 Installation

4.1 Safety Instructions

Warning!

Electrical parts apply voltage while in use. Disregard may result in death,

physical injury or damage to property. Therefore make sure that the

housing of the GC 5000 BTX is closed before switching on.

Caution!

Hydrogen is combustible and explosive. Therefore avoid wrong gas

connections. Disregard may result in damage to the system or cause

malfunction and wrong detection results. All gas connections to the GC

5000 are labeled: Make sure that the supply of the gases (hydrogen,

nitrogen, combustion air) is secured and the correct port for each gas line is

used before switching on the system.

Caution!

Make sure that the correct gas pressures are used as described in this

manual (see paragraph 4.3). Disregard may result in damage to the

system. Therefore use the correct pressure values for the gases (hydrogen,

nitrogen, combustion air) before switching on the system.

Caution!

Use nitrogen 5.0 (99,999%, GC-grade quality) as carrier gas and hydrogen

5.0 as combustion gas. Make sure that the combustion air is dry and free of

oil traces. Pure gases prevent the system from contamination.

Note

During operation of the instrument the ambient temperature has to be at

minimum 10°C below the starting temperature of the GC oven program in

order to guarantee a reliable cooling down of the GC oven at the end of

each cycle.

Note!

When using synthetic air with a very high purity instead of air from a zero

air generator as combustion air, make sure that the FID signal offset of the

FID amplifier is adjusted correctly (see chapter 13.3.5). The FID signal may

be lower with synthetic air than with zero air. If the signal is still < 100 mV

when the flame is lit, you will get an alarm message (see chapter 14.2 –

alarm 5.3).


Note

Electrical connections are displayed on the type plate on the rear panel of

the system.

4.2 Installation conditions

An appropriate location for installation of the GC 5000 should be vibration-

free as far as possible. The system is suitable to run in measurement

cabinets or containers.

Make sure that the ambient temperature should be in a temperature range

between 5°C and 35°C. Air conditioning has to be provided, if the

temperature exceeds that range. Keep in mind that the analyzer produces

waste heat, which has to be dissipated effectively.

Note

The ambient temperature during operation of the instrument has to be at

minimum 10°C below the starting temperature of the GC oven program in

order to guarantee a reliable cooling down of the GC oven at the end of

each cycle.

4.3 Gas connections

Bulkhead connectors for tube diameters of 1/8’’ (Swagelok) are provided to

connect the gas lines to the GC 5000.

The gas circuit diagrams as well as the type plate on the rear panel of the

GC 5000 indicate the correct port for each gas line to be connected.

• Use 1/8’’ PFA hose or stainless steel tubing to connect the gas lines.

• Use functional, leak proof and clean tubing only to connect the required

gases to the GC 5000.

• Pressure of combustion air: 2 bar (necessary for the FID flame).

• Pressure of the hydrogen: approx. 2 bar (necessary for the FID flame).

• Pressure of nitrogen: approx. 3 bar

Caution!

Hydrogen is combustible and explosive; avoid wrong gas connections.

Disregard may result in damage to the system or cause malfunction and

wrong detection results. All gas connections to the GC 5000 BTX are

labeled. Make sure that the supply of the gases (hydrogen, nitrogen,

combustion air) is secured and the correct port for each gas line is used

before switching on the system.

Caution!

Use nitrogen 5.0 (99.999%, GC grade quality) as carrier gas and hydrogen

5.0 as combustion gas. Make sure that the combustion air is dry and free of

oil traces. Pure gases prevent the system from contamination.

Gas pressures

Fittings


4.4 Electrical connections

For stand alone operation the analyzer requires an electric mains

connection. For remote control operation additional connections like

network, USB-, COM- or digital I/O are required. The power cord is

included within the scope of delivery.

The power supply (220-240V/50-60Hz) always has to be installed at last.

Note

Electrical connections are shown on the type plate on the rear panel of the

unit.

Warning!





5 Start up

5.1 Safety instructions

Warning!

Please read following operating instructions carefully before starting

operation.

Warning!




Caution!

Hydrogen is combustible and explosive. Disregard may result in damage to

the system or cause malfunction and wrong detection results. Therefore

avoid wrong gas connections: All gas connections to the GC 5000 are

labeled. Make sure that the supply of the gases (hydrogen, nitrogen,

combustion air) is secured and the correct port for each gas line is used

before switching on the system.

Caution!

Make sure that the correct gas pressures are used as described in this

manual (see paragraph 4.3). Disregard may result in damage to the

system. Therefore use the correct pressure values for the gases (hydrogen,

nitrogen, combustion air) before switching on the system.

Caution!

Use nitrogen 5.0 (99.999%, GC grade quality) as carrier gas and hydrogen

5.0 as combustion air. Make sure that the combustion air (zero gas) is dry

and free of oil traces. Pure gases prevent the system from contamination.

Note!


air generator as combustion air make sure that the FID signal-offset of the




alarm 5.3).


Note

Follow the start up instructions in the mentioned order. Disregard may

result in a detector ignition alarm or a carrier gas alarm and the analyzer is

not ready for operation.

5.2 Start up instruction

• Pressure of nitrogen: approx. 3 bar.

• Pressure of combustion air: 2 bar (necessary for the FID flame).

• Pressure of hydrogen: approx. 2 bar (necessary for the FID flame).

Follow the start up instructions in the mentioned order as described

below:

1. Connect all gas lines (as described in chapter 4.2)

2. Connect the digital I/Os, network at the designed ports at the back side

3. If required, connect keyboard and mouse at the front of the analyzer and

the monitor at the rear side of the analyzer.

4. Connect main power.

5. Open the gas supply of the carrier gas (nitrogen) and adjust the

pressure to approx. 3 bar.

6. While using a FID detector only, adjust the following gas pressures

additionally:

• combustion air supply to 2 bar

• hydrogen supply to 2 bar

7. Wait until all pressures have stabilized.

8. Switch on the analyzer.

• The power switch illuminates red.

• The operating system and the analyzer software start

automatically.

• The warm up starts:

All parts of the analyzer get heated to their set points (e.g.

detector, GC and valve oven). Using a FID detector the ignition

starts 1 minute after reaching 130°C.

The analyzer is ready for operation after some minutes of warm up. The

status color changes from yellow to green (displayed on the screen in

the grey bar at the left side down).

Gas pressures


Note!

After switching on the analyzer, it is possible that the enrichment stage

heats up to 230°C. This is not a malfunction. It cools down immediately to

the specified enrichment temperature.

Note!


air generator as combustion air make sure that the FID signal-offset of the




alarm 5.3).

Note

The colored field indicates the status of the system. Green: the analyzer is

ready to start and runs problem-free (see fig. below). Yellow: the system is

not ready as set points of the temperatures have not been reached. Red:

An alarm or error has occurred.


5. 3 Decommissioning

How to put the analyzer out of operation in case of repair or transportation:

1. Stop program. But do not close the gas lines!

2. Wait until the GC oven has cooled down to 50 °C.

3. Shut down the AMA control software and Windows.

4. Switch off the analyzer.

5. Close gas lines now.

6. Disconnect all gas lines from the analyzer.

7. Disconnect the analyzer from the mains supply.

Warning!


physical injury or damage to property. Therefore remove the power cable

before opening the device.

Note

Preparation for a saver shipment: If possible, use the original packaging of

the analyzer which is purpose-made. (It contains foamed plastic inserts

which are adapted to the size of the analyzer.)


6 Setting up the GC 5000 Software

The AMA control software allows an easy handling of the analyzer. It

informs the user via gas flow schemes and alarm windows about active

program steps, current pressure and temperatures values etc.

If the analyzer is not equipped with a touch screen monitor, a common

monitor, mouse and keyboard are required to edit parameters. But this

equipment is not necessarily needed for continuous measurements in the

field.

6.1 The status screen

During operation all important status information will be indicated on this

screen.

After turning-on the GC 5000 BTX

• The AMA control software and

• data acquisition program are automatically loaded.

• The monitor displays the following status screen:

This screen informs about

• current program steps

• current status of the system and

• temperature and pressure values.

Two time displays are placed in the lower part of the window:

• The remaining time for the current program step

• The time until the next run will start.

Note

All commands and functions for setting-up and operating the GC 5000 can

be activated via pull-down menus (as described in chapter 11.1.4.)


The colored field on the left indicates the status of the system:

Green The analyzer runs error free and it is ready to start.

Yellow The system is still not ready. When the GC temperature

program has already been started or when the system has just

powered up but the set points of the temperatures have not yet

been reached.

Red An alarm or error message has occurred.

A click on the colored bar informs about the current status:

Click on the yellow or red field: the following status display pops up.

All occurred information, alarms and errors are displayed here:

Click on the link „GC not ready“:

The next display informs about the current “Not ready” reasons of the

system:

Note

Potential reasons for the status “not ready”:

1. Differing temperature values of the GC oven or detector. This is the

case within the first 5 minutes after the system has been powered up.

2. When data acquisition has started, the analyzer is always in the status

“not ready”.

Colored bar indicates the status

Check the status


6.2 How to unlock – Password protection

To avoid an unauthorized access to the parameter editors the AMA control

software is equipped with a password protection.

Menu bar →→→→ Unlock

1. “Unlock” has to be activated before parameters can be saved.

The following window will pop up:

2. Enter the password (as a numeric code) and press “E”.

3. After modification all parameters can be saved now. Entering a wrong

password will cause an error message.

Now the menu item “Unlock” switches to “Lock” in the menu bar.

Note

If you do not select a password, i.e. the password is empty, you will not

have a password protection. In this case the input window will not pop up

and the saving of modifications is enabled immediately without protection.

Password protection


6.3 How to select operation modes

Menu bar

Parameters Operation mode

The GC 5000 can be operated in three different operation modes:

1. Manual operation

After clicking onto the “Start” button the analyzer performs one run and

waits for the next click onto the “Start” button.

2. Cyclic mode

The analyzer starts the next cycle after the specified cycle time.

3. Remote control

The analyzer waits for a new cycle start via the communication protocol

(Gesytec II) after each run.

6.4 How to select master mode

Menu bar

Parameters Master mode

If you have an ozone precursors system (one BTX analyzer and one VOC

analyzer) you can switch on the master mode and set the VOC analyzer

into slave mode.

Then the BTX analyzer is the master and controls the VOC analyzer (the

slave).

Each cycle and the calibrations are started by the BTX analyzer. So the two

analyzers are running synchronously.

Note

It is necessary that both analyzers have the same operation mode, the

same number of calibration levels, the same calibration setup and the

same validation setup.


6.5 How to select communication parameters (optional)

6.5.1 Analog outputs configuration

Menu bar

Parameters Analog output conf.

If you have a board with 4, 8 or 16 analog outputs in your analyzer, you can

edit the configuration and correlation between outputs and results in this

window.

1. Select the mode of the desired output type under „Analog output type“.

The resolution of the voltage outputs is 1.22mV and the resolution of the

current outputs is 2.7µA.

2. Select for every channel a component from the results file of the

chromatography software (Drop-down menu).

3. Edit the low and high range values.

Referring to the selected values displayed in the window above, we get the

following results :

• All analog outputs (4) got the type 0-10V.

• Channel 1: It shows the result for benzene.

The output voltage of channel 1 will range linear between 0V for 0ppb

benzene and 10V for 10ppb benzene.

• Channel 2:

It shows equivalent 0V for 5ppb toluene and 10V for 100ppb toluene.

The same is valid for the channels 3, 4 and 5 for the other components.

The channels 6 to 8 will not be used.


Fig.5: Connection of analog outputs


6.5.2 Alarm configuration

Menu bar

Parameters Alarm config.

If you have a board with digital outputs in your analyzer, you can edit the

configuration of the four alarm outputs in this window.

1. Select the components from the calibration file in the drop-down list. You

can configure several alarms for one component.

2. Select the type of alarm (high alarm or low alarm) for each output.

3. Edit the alarm threshold for each output.

Note: This concentration must be exceeded / under-run to activate the

alarm. If the alarm threshold is 5 ppb and the measurement value is 5

ppb, then the alarm is not activated.


following results:

• Alarm 1 is activated when the concentration of benzene exceeds 5 ppb.

• Alarm 2 is activated when the concentration of benzene exceeds 10

ppb.

• Alarm 3 is activated when the concentration of toluene exceeds 20 ppb.

• Alarm 4 is activated when the concentration of m,p-xylene falls below

1 ppb.


6.5.3 Gesytec specifications

Menu bar

Parameters Remote control Gesytec specifications

In this menu you can modify the parameters for the communication via the

Gesytec II protocol.


Service mode:

The service mode has to be activated before doing maintenance work while

the analyzer is operating. Then the analyzer does not accept any control

commands from the PC of the monitoring station. In this case controlling is

only possible by the analyzers software but results and status are still

transmitted.

6.5.4 Modifying of parameters under “Gesytec specifications”:

Remote control Gesytec specifications COM Parameter:

This interface will be used for data transfer between analyzer and

monitoring station main computer via the Gesytec II protocol. For this

purpose, the transfer speed can be selected in a range of 1200 to 19200

Baud.

The default value is „9600“.

• The Save value menu makes the inputs active.

• With the Quit button you can leave this window without any change.

COM Parameter


Remote control Gesytec specifications ID Code:

Using the Gesytec II protocol the analyzer is able to transmit up to 48

results.

Codes are combined to 6 blocks of 8 components each. So in accordance

to the application, 8, 16, 24, 32, 40 or 48 component data blocks can be

transmitted.

You have to enter each code here as this protocol needs two codes for

calling each result.

The serial numbers and ID-codes which are necessary for data transfer

have to be edited for each component:

• The Save menu makes the inputs active.

• The Quit button leaves this window without any change.

Remote control Gesytec specifications Number of components:

Here you can select whether 8, 16, 24, 32, 40 or 48 results are transmitted.

The following window pops up:

The Gesytec II standard allows only 20 results. If more results have to be

transmitted the monitoring stations PC must be able to handle them. See

chapter 17.

ID Codes

Number of components


Remote control Gesytec specifications

Validation / Calibration on cal. Gas on request Cal

Val

In case a calibration run starts via protocol you have to select if the run is

handled as a new calibration (Cal) or validation (Val, no new calibration

data is produced). In both cases calibration valves or modules are switched

to the corresponding calibration input or level.

The following charts show the configuration of the data bytes which can be

sent from the GC 5000 BTX via the Gesytec II protocol.

Control byte

Bit 0 Start sampling

Bit 1 Zero gas on (calibration gas 1)

Bit 2 Span gas on (calibration gas 2)

Bit 3 Not used

Bit 4 Not used

Bit 5 Not used

Bit 6 Not used

Bit 7 Not used

Status byte

Bit 0 System off

Bit 1 Maintenance / Stand alone mode

Bit 2 Zero gas running (calibration gas 1)

Bit 3 Span gas running (calibration gas 2)

Bit 4 Program step sampling running

Bit 5 New results

Bit 6 Not used

Bit 7 Not ready

Error byte

Bit 0 Pre-cooling alarm enrichment stage

Bit 1 Sample alarm

Bit 2 Carrier gas alarm

Bit 3 Ignition of FID not possible

Bit 4 FID too cold

Bit 5 FID too cold for 8 minutes

Bit 6 Not used

Bit 7 Communication breakdown to MFC /

Temp. controller

Status and error byte show the current status of the analyzer.

Note: The status and error bytes will be transmitted as well. While

transmitting results, these status and error bytes indicate the analyzer

status during data acquisition only.

Protocol bytes

Validation/ Calibration on calibration gas on request


7 Starting operation

The required application for your analyzer is already configured by AMA

Instruments. So there is no need to develop a method for operation.

7.1 How to start measurements

1. Click onto the start button. Then a small window pops up:

2. If you click on ok: The cycle immediately starts.

or

3. If you check “Set time for start” a new input area appears:

4. Enter the time for the start in the 24 hours format,

i.e. 18 o’clock means 6 o’clock pm.

The analyzer waits until this time and then starts the cycle.


You can monitor the current program step in the program window of the

AMA control software after the analyzer has started:

When the injection starts, the GC temperature program and acquisition

of chromatogram start as well.

You can see the real-time chromatogram in the data acquisition window:

Monitoring of measurement


Menu bar View Last results

After the chromatogram is completed, you can see the results:

Menu bar View Results table

All results of the runs are listed:

With >copy and paste< you can import the list into an excel file.


7.2 How to adjust the retention time windows

If you find 0.00 results although the peaks are present in the

chromatogram, the retention time windows are not at the correct position

and have to be adjusted.

1. Menu bar Parameters CP Analysis

Load the last chromatogram in the CP Analysis module

Note: You should have recorded at least three chromatograms to make

sure that the system runs stable now. This means as well that the first

run should be discarded.

You can load several chromatograms at the same time:

Select them in File open dialog with

Ctrl/Shift and mouse-click before clicking “Open”.

2. Menu bar Compare Overlay

Mark „Overlay“ in the menu „Compare“.

Overlay of all chromatograms: They are listed on top of each other

instead of each one in a separate window.

How to load a chromatogram


3. Menu bar Compare Synchronize Expansion

All overlaid chromatograms can be zoomed the same way at the

same time.

In this window, the overlay is displayed more comfortable.


There are two different ways to modify the retention windows:

1. Input new values under „Edit Numeric“

Menu bar Tools Modify Components Edit Numeric

or alternatively

2. Drag and click with the mouse under „Edit Graphic“

Menu bar Tools Modify Components Edit Graphic

3. When you click on Edit Numeric a window pops-up after clicking onto

a peak name.

In this window you can modify

• name

• expected retention time

• half retention window width.

In the lower left corner of the screen you can see an additional window with

further instructions.

Or alternatively

3. By clicking onEdit Graphic some markers appear in the

chromatogram:

4. Enlarge or downsize the retention window by dragging of the blue edge

markers.

How to modify the retention time windows


5. Move the position of the retention window by dragging the lower marker

with the peak name inside.

When all retention windows are adjusted

save the new values by clicking

Menu bar →→→→ File →→→→ Save calibration

In this case only the retention times are modified not the response values.

How to save window adjustments


7.3 How to zoom / zoom out the chromatogram

In some cases it is difficult to adjust the retention windows in the standard

view.

1. Enlarge or downsize the view of the chromatogram by

→→→→ Right-click into the chromatogram window →→→→ select Scale


2. Enter the limits of the part of the chromatogram which you want to see in

the chromatogram window.

3. Click on “OK”: This activates the new values and closes the window.

Or alternatively

Click on “Apply”:

This activates the new values as well but does not close the window. In

this case, you can check first if the new values are ok or modify them

again before closing this window.

1st possibility to zoom:


Another possibility to enlarge a part of a chromatogram is the following:

1. Click and hold the left mouse button.

2. Move the mouse by surrounding the part of the chromatogram and

release the left mouse button.

3. Activate the zoom by clicking the right mouse button.

You can cancel the zoom by

→→→→ Right-click into the chromatogram window

→→→→ Select Undo Expansion

How to zoom out

2nd possibility to zoom:


7.4 How to optimize integration parameters

The integration parameters can be optimized if necessary:

1. Load the last chromatograms.

2. Check the integration baseline.

In the menu bar “Integration” you find the commands for moving,

adding or deleting integration events.

3. Click on „Insert Event“.


All possible events with their effects are listed after clicking onto them.

4. Save all adjusted integration parameters:

Menu bar →→→→file →→→→ Save method

Now the system is ready for measuring operation.


8.0 Using LCD display and buttons on the front panel

Generally the basic version of a GC 5000 Analyzer (BTX or VOC or

Process) is equipped with a LCD display and 4 buttons in the front panel.

This chapter illustrates the configuration and operation of this LCD display

with screenshot examples.

The following basic functions can be done without connecting a monitor:

• start or stop

• remote control on or off

• list of errors

• the results of the last run

After power on the analyzer an initialization text will be seen in the display

for about 10 seconds.

Afterwards the following text appears in the display:

First row: informs about the type of analyzer (e.g. GC 5000 BTX).

Second row: displays the current program step on the left and on the right

about the GC status (ready or not ready).

Third row: is reserved for special information.

Fourth row: always displays the function of the buttons below. As shown

in example above this means:

left button: Start or stop of the sample program

button “Mode”: configures the remote control

button “Results” : show the results of the last run

button “Status”: displays occurred errors and the current

sample line.


Button „Mode“:

It displays the current status

Remote control Can be selected or not (done by the left

button)

Maintenance mode Is only available when remote control has

been selected (switched on or off with the

“Maintenance button”.

Exit Press this button in order to return to the main

menu.

Button „Results“:

It lists the results of the last run.

If there are more than 3 results: scroll the display with the “Up” or “Down”

buttons

Button “Exit”: Return to the main menu


Button „Status“:

It displays the next information level: Channel and Errors.

Button “Channel”:

It displays the current input channel (sample 1 -6, calibration gas 1 – 2).

Some inputs are only available with a calibration gas selector or a sample

stream selector.

Button “Errors”:

It lists all errors which were detected. In the example below no error

message has been detected.

Press “More”: Further error messages are listed if there are any.


9 Calibrating and validating GC 5000 BTX

9.1 Calibration

9.1.1 Calibration intervals

A GC 5000 BTX needs to be calibrated from time to time. It depends on the

stability of the detector:

Note

Calibration intervals for GC 5000 BTX: By using a FID detector a three

month interval is sufficient, with a PID detector a calibration interval once a

month is recommended.

A FID detector is very stable and does not have a significant drift after 3

months. Thus it is enough to calibrate the system not more than every three

months.

A PID detector has a natural drift because of the aging of the PID lamp.

Therefore it is recommended to calibrate the system once a month.

The AMA control software contains the necessary features for doing the

calibration manually or automatically.


9.2 How to enter the data of calibration gas concentrations

9.2.1 Enter the data – without a calibration gas module

This chapter explains how to enter the concentrations of the span gas cylinder or other calibration levels.

Menu bar Parameters Calibration Calibration gas

concentration

This menu item is only enabled if you do not have a calibration gas module.

Whereas a calibration gas module has to be configured in the module

setup (see next paragraph 9.2.2).

1. Select a component from the left side and edit the concentration values

in all activated levels.

2. Save the values by clicking “Save values”.

9.2.2 How to disable concentration levels

In case you want to use less concentration levels than are present in the

calibration file, you have to disable the concentration levels which are not in

use.

1. Remove the check mark from the check box which is left from the level

name.

The selected concentration level is disabled. This means that it is

disabled for all components at once.

Note

A flame ionization detector (FID) is characterized by its linear detector

response. Thus only two concentration levels are required for a proper

calibration of the analyzer. By contrast a photo ionization detector (PID)

does not show a linear detector response. Therefore a minimum of 4 to 5

calibration levels are recommended for proper calibration of the analyzer.


9.2.3 Enter the data – with a calibration gas module

If you have a dilution gas module, this will be configured in the module

setup:

Menu bar Parameters Module setup Dilution module

Calibration gas source concentration setup

1. Enter the concentrations of the source calibration gas cylinder.

2. Select up to four main components out of all components from the

calibration file.

These up to four components and their concentrations are listed on the

display of the DIM 200 (calibration gas module) for all calibration levels.

3. Save your modifications: by clicking “Save setup”

Note: In case you leave the window by clicking the “Quit” button, the

modifications are not saved.

4. When you try to save the new values, the following windows appears

first:


5. Press “Yes” and the following window automatically pops up:

Alternatively you can open this window as follows:

Menu bar Parameters Module setup

Dilution module Dilution module setup

1. On this window you can enter the concentrations for each calibration

level.

It is sufficient to enter the concentration for one component or the

dilution factor and the other concentrations are automatically calculated.

The dilution factor X means that the resulting concentration is 1/X of the

source concentration.

2. In the first row you can enable or disable calibration levels but only

levels which are present in the calibration file.

3. If you want to have more levels you have to add them with the Chrom

Perfect File Editor (See chapter 11.3.12 for further information.)

4. After you have entered the correct values, click “Save setup” to save the

parameters.

Note







9.3 How to start a calibration

9.3.1 Calibration of one calibration level (with and without calibration module)

1. Start a manual calibration of one calibration level by selecting

Menu bar Run calibration Manual calibration Level x

2. Select the calibration level


3. Select the number of runs for the calibration level and click on the check

box if the result of the first run has to be discarded.

The calibration of one calibration level is activated.

In this example the level is calibrated with the average value of the

second and the third run.

Manual calibration


9.3.2 Calibration sequence (without calibration module or cal. valves)

The system is configured by AMA Instruments with the following items:

o number of runs per level: 1

o the results of the first run is not discarded

How to change the pre-configured parameters:

1. Select Menu bar Parameters Calibration Calibration setup

2. Select the number of runs for the calibration level

3. Click on the check box if the result of the first run has to be discarded.

The parameters are changed now.

1. For the run of an auto-calibration without calibration module or built-in

calibration valves select:

Menu bar Run calibration Manual calibration sequence

Prior to each calibration level the following window pops up:

2. Connect the correct calibration gas to the sample port and press “Start”.

After the analyzer did the number of runs, it asks you to connect the

next calibration gas to the sample port.

3. Press “Start” again.

The calibration sequence is manually activated.

Sequence

Setup


9.4 Auto-calibration

This paragraph describes the fully automatic calibration for all calibration

levels.

This function is only activated if the system features

• built-in calibration gas valves (with up to two calibration levels) or

• an external calibration gas module (e.g. DIM 200 with up to 20

calibration levels).

Menu bar Parameters Calibration Calibration setup

1. Select the number of runs per level between 1 and 9

2. If the results of the first run should be discarded, click on this box.

The other parameters are already configured by AMA Instruments.

Save the parameters and the auto-calibration can be started.

Menu bar Run Calibration Auto-Calibration

Here you can start a fully automatic calibration for all calibration levels at

once.

After the analyzer did the number of selected runs of the first calibration

level, it automatically switches to the calibration gas of the next level and

does the next runs.

The analyzer stops after finishing all runs of the last calibration level.

Run of calibration


9.5 Validation

9.5.1 Principle of validation

A validation is a run with zero gas and /or a span gas in order to check the

drift, repeatability and/or memory effects.

The run is treated as a regular sample, i.e. no new calibration data will be

produced.

1. You need built-in calibration valves or a calibration gas module to do a

validation.

2. Type of gas:

The gas for the validation may not be the same which is also used for

the calibration of the system. You can use a gas with only one of the

components from the calibration file.

9.5.2 Types of validation

The initial validation produces the original data which is needed for the

calculations as the results of the standard validation are compared with the

values of the initial validation e.g. a drift check has been performed.

An initial validation has to be done

• before a standard validation runs for the first time.

• after a calibration has been performed.

• when the validation gas has been changed

Menu bar Run validation Initial validation

After selection of this menu item the analyzer starts doing the initial

validation. It stops after the validation is completed.

Menu bar Run validation standard validation

Here you can start a standard validation.

If you select this menu item the analyzer starts to do the standard

validation.

The analyzer stops after the validation is completed.

The analyzer runs an automatic validation as well if configured in the

validation setup: Menu bar Parameters Validation setup

This menu item is only activated if the analyzer

• is equipped with built-in calibration valves

or

• it has been connected to an external calibration module.

Definition

System requirements

Initial validation

Standard validation


9.5.3 How to start validation

Configure the type of tests the system should do:

1. Select the menu item “Validation setup”

Menu bar Parameters Validation setup

2. Click on the relevant boxes the type of tests which should run:

Zero gas check It checks for memory effect or contamination

Drift check It checks for a deviation between the original span

value and the current span value

Deviation value It checks for a deviation between two current span

values

Run auto-validation If a validation shall start automatically either after a

number of cycles or at a definite time.

3. Select the zero gas supply and the span gas supply:

These items select the corresponding inputs when using calibration

valves or the corresponding levels when using a calibration module.

4. Select the relevant components for the validation

Menu bar Select components

1. Step: Configuration

4 types of validation tests


Explanation to the entries in this window:

1. First column: Select the components which shall be included in the

validation.

2. Second column: List the names of the components.

3. Other columns: Here you can specify the limits for the warning level or

for the error level.

The configuration of the tests is completed.

• Warning level:

You get a message if it is reached but the program will continue. A

warning level in the drift check can be used to do an auto-calibration.

• Error level:

You get a message and the program will stop because the system must

have a problem which should be fixed first.

Example of limits for warning and error levels:

In the window above the following example lists the limits which are defined

as warning and error levels for benzene.

Zero gas check Warning level 0.3 ppb

Error level 0.6 ppb

Drift check Warning level 5%

Error level 10%

Deviation check Warning level 2%

Error level 4%

Definition


How to run initial validation:

1. Select


Note

Before running a standard validation for the first time, an initial validation

has to be performed. As well it is necessary to run an initial validation after

each calibration. An initial validation has to be performed at any time, when

the validation gas has been changed.

Depending on the setting for “run initial validation after auto-calibration or

manual sequence” (see check box on window below)

the analyzer will run automatically an initial validation either directly when a

calibration sequence has been completed or during the next scheduled

validation run.

How to run standard validation:

There are two possibilities to run a standard validation. It depends on

whether to run it manually or automatically.

1. Start a run manually: select

Menu bar Run validation Standard validation

Alternatively:

2. Start an automatic run:

Press the “Start” button on the main screen.

The validation starts after the specified cycles or time as this parameter

have been set in the validation setup.

2. Step: Run initial validation

Automatic initial validation

3. Step: Standard validation


3. Check validation status:

Select Menu bar View Validation status

In this window the result is displayed after a validation sequence has

completed. In the example below every check is within the defined limits.

• Green indicates that the validation run of all tests is ok.

• Yellow indicates that the limit is reached (warning level)

• Red indicates that the values exceed the limit (error level). For further

information and definition see page 60.

3. Check the exact results by opening e.g. the file

c:\cpdata\gc5000\VALBenzene.btx.met.txt

in case Benzene has been used for validations.

Note

The name of the file consists of VAL + component name + method name +

.txt.

The columns of the file contain the following information:

• Counter

• “I” for initial validation / “S” for standard validation

• Name of chromatogram for zero gas check

• Date and time of chromatogram for zero gas check

• Result of chromatogram for zero gas check

• Name of chromatogram for drift check

• Date and time of chromatogram for drift check

• Result of chromatogram for drift check

• Name of chromatogram for deviation check

• Date and time of chromatogram for deviation check

• Result time of chromatogram for deviation check

• Drift

• Deviation

Structure of file:


• The result of the zero gas run is equal the zero gas deviation.

• The drift is calculated from the difference from the actual result and the

result from the initial validation.

• The deviation is calculated from the difference of two actual results

(chromatogram for drift check and chromatogram for deviation check).

Calculation basis of deviation and drift:


10 Functional description

This chapter refers especially to personnel who is in charge of

maintenance work or applications.

10.1 Measuring principle

The AMA BTX Analyzer is a system for automatic sampling, enrichment

and GC analysis, regarding the following organic substances:

The measurement is based on the principle of adsorption of compounds on

special materials in an enrichment tube and detection of the organic

compounds with the help of a FID or a PID detector after separation on a

capillary column of a GC.

Fig. 6: Time program (example):

1. Purging time sample line:

The sample line is purged with sample gas to make sure that actual

sample gas is available when starting the next step.

2. Enrichment on the BTX-tube:

A definite volume of ambient air (regulated flow with a thermal mass

flow controller, in the further text always called MFC) is sucked through

an enrichment tube (BTX-tube), which is filled with adsorbent

material.

3. Injection:

After enrichment the BTX-tube is heated in a very fast way and the

adsorbed materials are vaporized again and flushed onto the capillary

column of the gas chromatograph module.

Steps of operation:


4. Separation by gas chromatography and Analysis of data:

A gas chromatographic capillary column is used to separate the

sampled objects. The separated compounds are detected by a FID or a

PID. The measured peak areas can be compared with the function of

calibration.

5. Waiting for cycle time and cooling down the BTX-tube:

Before the next start of sampling the enrichment stage is cooled down to

the enrichment temperature.

10.2 Definition of the program parameters

1. Purging time:

The sample line will get flushed with sample or calibration gas for this

time.

2. Enrichment temperature:

The enrichment stage has to be cooled down to this value (+/-5°C)

before the sampling will get started automatically.

3. Sampling time:

During this time the programmed sample volume has to be sucked

through the enrichment stage.

4. Sample volume:

This is the set point of the volume which has to be sucked through the

enrichment stage during sampling.

5. Calculated gas flow:

The shown value of the sucking velocity during sampling is calculated as

the quotient of the sample volume and the sample time less 10 seconds.

This subtraction is made to get a little time buffer for starting the MFC.

Note

The value will be calculated after saving the set points as current values,

before the previous value is shown.

6. Injection temperature:

The enrichment stage will be heated to this temperature value during the

program step injection.

7. Injection time:

The vaporized sample will be transferred from the hot enrichment stage

to the GC column during this program step. Simultaneously the GC

temperature program and the data acquisition are started.

8. Cycle time:

The cycle time is the time between two starts of sampling.


9. Valve oven temperature:

The valve oven will get heated to this temperature value. It has to be in

the range of +40°C to +150°C.

10. Detector temperature:

The detector will get heated to this temperature value. It has to be in

the range of +130°C to +200°C for a FID detector or in the range of

+40°C to +150°C for a PID detector.

11. Hydrogen flow:

If you have a FID you can enter the hydrogen flow for the detector

here. The flow is regulated by a mass flow controller. The range is

from 25 ml/min to 75 ml/min. Standard is 40 ml/min.

12. Chrom Perfect method

In this menu item you can select the method for the chromatographic

analysis. See chapter 11.4.2.11 for more information about the Chrom

Perfect method.


10.3 Program example

• After starting the sample program the pump will get started and the

sample line will get flushed for two minutes (purging time) with sample

gas.

• Simultaneously the enrichment tube will be cooled down to 30°C

(sampling temperature).

• Next VE1 is switched and sampling starts with a flow of 21ml/min

(calculated gas flow) until a volume of 300ml (sample volume) is sucked

through the enrichment tube.

• Now the CP method (sample or calibration) is loaded and VE1 is

switched back.

• The enrichment tube gets heated very quickly up to 230°C (Injection

temperature).

• Simultaneously the GC oven program is started and data acquisition

begins.

• 3 minutes (Injection time) later the enrichment tube starts to cool down

to the sampling temperature of 30°C and the system is ready for the

next start.

• This start may occur before the GC oven temperature program was

finished.


11 Software reference

11.1 Basic software design

11.1.1 Software architecture

The software of the GC 5000 consists of two parts, the controlling software

GC 5000 BTX and the chromatography software Chrom Perfect.

All functions of the system are controlled via the GC 5000 BTX software,

except modification of retention windows, integration parameters as well as

reintegration of chromatograms

The Chrom Perfect software records the chromatograms, analyzes them

und passes the results via a file link to the GC 5000 BTX program.

Note

Do never close the Chrom Perfect data acquisition window after switching

on the analyzer as the DDE connection between both programs would be

broken. This mistake causes an error message while the AMA control

software stops immediately. After 30 seconds the hardware watchdog

restarts the internal PC again automatically.

11.1.2 Configuration files

There are three different configuration files:

• GC 5000 method file (.mth)

• Chrom Perfect method file (.met)

• Chrom Perfect calibration file (.cal).

GC 5000

method

It contains all necessary parameters for the controlling of

the GC 5000, like temperatures, program step times, the

GC oven program and the name of the Chrom Perfect

method.

Chrom Perfect

method

It contains all necessary parameters for the recording

and analysis of the chromatogram and the name of the

Chrom Perfect calibration file.

Chrom Perfect

calibration file

It contains the component table with the retention times

and the calibration data like fitting type and response

values.


11.1.3 Main window: Program

This is the most important window of the AMA control software and

normally the one, which is displayed on the screen.

1. This window informs about

• the current program step,

• the current status of the system and

• the temperature and pressure values.

2. Two time displays are placed in the lower part of the window.:

• The first one displays the remaining time for the current

program step

• The second one displays the time until the next run will start.

3. The menu bar on top of the screen list the menu items. These are

described in detail in this chapter.

4. The colored field on the left indicates the status of the system:

Green The analyzer runs error free and it is ready to start.

Yellow The system is still not ready. When the GC temperature

program has been already started or when the system has

just powered up but the set points of the temperatures have

not yet been reached.

Red An alarm or error message has occurred.

A click on the bar informs about the current status details (see next page).


A click on the yellow or red field opens the status display.

All occurred alarms and errors will be shown here:

Clicking the button „GC not ready“:

It informs about the “Not ready” reasons of the system.

Note

Potential reasons for “not ready”:

1. Differing temperature values of the GC oven or detector. This is the

case within the first 5 minutes after the system has been powered up.

2. When data acquisition has started, the analyzer is always in the status

“not ready”.

Check on the status bar


11.1.4 Menu items

The menu bar of the main window above contains the following

menu items:

• Unlock

• Parameters

• Program steps

• View

• Run calibration

• Run validation

• Help

They are described in detail on the following pages in the following

chapters.


11.2 Unlock

The AMA control software is equipped with a password protection to avoid

an unauthorized access to the parameter editors

Menu bar Unlock

has to be activated before modifications of parameters can be saved.


1. Enter the password (as numeric code) and press “E”.

2. After modification all parameters can be saved now. Entering a wrong

password will cause an error message.

Note

If you do not select a password, i.e. the password is empty: In this case the

input box will not pop up. The saving of modifications is enabled but

without protection.

Note

Before starting the CP File Editor or CP Analysis “Unlock” has to be

activated. Otherwise these menu items are disabled.


11.3 Parameters

In this menu item you can edit parameters like temperatures or times.

Menu bar Parameter

Select between the following parameters:

• Change password

• Operation mode

• Remote control

• Master mode

• Method

• Analysis

• GC oven

• Calibration

• Validation setup

• Analog output configuration

• CP Analysis

• CP File Editor

• Module setup

11.3.1 Change password

Menu bar Parameter Change password

When you click on “Change password” the earlier described input box pops

up (see chapter 11.4.1).

Enter the new code and click onto “E”.

The new password is active now.

11.3.2 Operation mode

Menu bar Parameter Operation mode

In this menu item you can select between three different modes:

• “Manual operation”:

The analyzer starts one run after clicking onto the “Start” button and

waits for the next click onto the “Start” button.

• “Cyclic mode”:

The analyzer starts the next cycle after the specified cycle time.

• “Remote control”:

The analyzer waits for a new cycle start via the communication protocol

after each run.


11.3.3 Remote control

Menu bar Parameter Remote control

In this menu item you can modify the parameters for the communication via

the Gesytec II protocol.


Service mode:

The service mode has to be activated before doing maintenance work while

the analyzer is operating. Then the analyzer does not accept any control

commands from the monitoring stations PC. Controlling is only possible by

the analyzers software. Results and status are still transmitted.

Menu bar Parameter Gesytec specifications

The following parameters can be modified:

Remote control Gesytec specifications COM Parameter

This interface will be used for data transfer between analyzer and main

computer of the monitoring station via the Gesytec II protocol. For this

purpose, the transfer speed can be selected in a range of 1200 to 19200

Baud. The default value is „9600“.

• Clicking on menu item Save value makes the inputs active.


COM Parameter


Remote control Gesytec specifications ID-Codes

Using the Gesytec II protocol the analyzer is able to transmit up to 48

results.

Codes are combined to 6 blocks of 8 components each. So in accordance

to the application, 8, 16, 24, 32, 40 or 48 component data blocks can be

transmitted.

As this protocol needs two codes for calling each result you have to enter

each code in the following window:

The serial numbers and ID-codes which are necessary for data transfer

have to be edited for each component:

• Clicking on menu item Save value makes the inputs active.


Remote control Gesytec specifications Number of components:


1. Select the number of transmitted results: 8, 16, 24, 32, 40 or 48.

The Gesytec II standard normally allows only 20 results. If more results are

to be transmitted PC of the monitoring stations must be able to handle

them. See chapter 17.

ID-Codes

Number of components


Remote control Gesytec specifications

Validation / Calibration on cal. Gas on request Cal

Val

In case a calibration run starts via protocol you have to select if the run is

handled as a new calibration (Cal) or validation (Val). In case of

selection “Validation” no new calibration data is produced. In both cases

calibration valves or modules are switched to the corresponding calibration

input or level.

Gesytec specifications Protocol bytes

The following charts show the configuration of the data bytes which can be

sent from the GC 5000 BTX analyzer via the Gesytec II protocol.

Control byte

Bit 0 Start sampling

Bit 1 Zero gas on (calibration gas 1)

Bit 2 Span gas on (calibration gas 2)

Bit 3 Not used

Bit 4 Not used

Bit 5 Not used

Bit 6 Not used

Bit 7 Not used

Status byte

Bit 0 System off

Bit 1 Maintenance / Stand alone mode

Bit 2 Zero gas running (calibration gas 1)

Bit 3 Span gas running (calibration gas 2)

Bit 4 Program step sampling running

Bit 5 New results

Bit 6 Not used

Bit 7 Not ready

Error byte

Bit 0 Pre-cooling alarm enrichment stage

Bit 1 Sample alarm

Bit 2 Carrier gas alarm

Bit 3 Ignition of FID not possible

Bit 4 FID too cold

Bit 5 FID too cold for 8 minutes

Bit 6 Not used

Bit 7 Communication breakdown to MFC /

Temp. controller

Status and error byte show the current status of the analyzer.

Note: The status and error bytes will be transmitted as well. While

transmitting results, these status and error bytes indicate the analyzer

status during data acquisition only.

Protocol bytes

Validation/ Calibration on calibration gas on request


11.3.4 Master mode

Menu bar Parameter Master mode

If you have an ozone precursors system (one GC 5000 BTX analyzer and

one GC 5000 VOC analyzer) you can switch on the master mode and set

the VOC analyzer into slave mode.

In this case the BTX analyzer is the master and controls the VOC analyzer

(the slave). Each cycle and calibrations are started by the BTX analyzer. So

the two analyzers are running synchronously.

Note

It is necessary that both analyzers have the same operation mode, the

same number of calibration levels and the same calibration setup. In case a

complete ozone precursor system (GC 5000 BTX and GC 5000 VOC) is

manufactured at the same time by AMA Instruments, the parameters are

configured ex factory .

11.3.5 Method

Menu bar Parameter Method

The current set of parameters can be saved as a method or a new set of

parameters can be loaded.


1. Select a saved method and after clicking onto “Open” it is loaded.

2. Analog you can save a set of parameters as a method with clicking onto

“Save”.


11.3.6 Analysis

Menu bar Parameter Analysis


Every value of the sample and enrichment program which can be modified

is displayed in this window. These are:

• Different times as sampling or injection time in minutes and seconds,

cycle time in hours, minutes and seconds.

• Sample volume, the temperature values for the enrichment tube, the

valve oven and the detector can be modified.

How to change any value:

1. Click on its input field, e.g. “sampling time” (see window above).

The following numeric window pops up and you can enter the new

value. In the upper part the value is displayed in the box.

2. Enter the new value in the box and press “E” (enter)

3. Save the parameters after editing:

Menu item Save as actual values

Note

1. In case that all values are in the permitted range, the analyzer will

accept them immediately and the parameter window will get closed.

2. If a value is erroneous (e.g. a temperature value is too low or too high)

an error message will occur and the old values will stay active.


11.3.7 GC Oven

Menu bar Parameter GC oven


Every value of the GC program which can be modified is displayed in that

window. These are

• the initial temperature

• the initial time for the first phase

• values for heating rate

• final temperature

• final time for the next three phases.

How to calculate the new total time of the GC program:

1. Modify any value by clicking on the relevant input box.

2. Enter the numeric field in the numeric window and press enter “E”.

3. Click on the button „Calculate“

The edited GC program will be calculated and the total time will be

displayed. Attention: The values have not been saved yet.

How to display a diagram of the GC program:

1. Modify any value by clicking on the relevant input box.

2. Enter the numeric field in the window and press enter “E”.

3. Click on the button „Diagram“

The modified diagram will be displayed:


How to run a GC oven program with less than 3 heating ramps:

1. Set the heating rate for the first not used temperature phase to zero.

In the example above the GC program finish after the end of final time 1.

Note

Check the starting temperature of the GC oven program. The ambient

temperature during operation of the instrument has to be at minimum 10°C

below the starting temperature of the GC oven program in order to

guarantee reliable cooling down of the GC oven at the end of each cycle.


11.3.8 Calibration

Menu bar Parameter Calibration

You can select between:

• Calibration setup

• Calibration gas concentration

Menu bar Parameter Calibration calibration gas setup

The AMA GC-5000 control software features a calibration setup.

If the optional calibration gas valves are installed, this software part controls

them:

1. Connect zero gas and span gas to the appropriate inputs of the analyzer

(see chapter 3.5.1).

If an external calibration gas unit like a permeation module or a dilution

module is connected, the module has priority over the internal valves and

the module controls the calibration levels. (See chapter 3.5.3 for more

details about gas calibration modules.)

2. Select the number of cycles per calibration level.

3. Place a check mark to “discard the first run per level” if the results of the

first run for each level always should be discarded.

4. Place a check mark at “run auto calibration” in this window if the

analyzer should run it.

Another check box appears as there are three possibilities now to run an

auto-calibration:

• after a specified number of cycles

• at a specified time

• or when the validation drift check exceeds the warning level

Calibration setup


According to the example in the window above, the following entries

describe an auto-calibration after a specified number of cycles:

5. Select the radio button “Number of sample cycles”.

In this example the analyzer runs

• 50 sample cycles

• 2 runs for each calibration level

• discards the first run of each level.

Then the analyzer will do 50 sample cycles again.

Alternative: to run an auto-calibration at a specified time as it is displayed in

the window below:

6. Select the radio button “Date/Time”

Another input data area “auto calibration setup” appears as displayed

below:

7. Select the following parameter in that input data area

• period between calibrations

• date

• day and time if necessary.

Note

The input of the time has to be entered in a 24 hours format, i.e. 10 o’clock

pm has to be entered as 22 o’clock.


Menu bar Parameter Calibration calibration gas concentration

This menu item is only visible if you do not have connected a calibration

gas module.

Enter the concentrations in the span gas cylinder or other calibration levels

in this window:

1. Select a component from the left side and

2. Edit the concentration values in all selected levels.

3. Save the values by clicking “Save values”.

It is possible to disable a calibration level as well:

1. Remove the check mark from the check box left from the level name.

The selected concentration level is disabled. This means that it is

disabled for all components at once.

Note






If you want to add components or levels you have to use the Chrom Perfect

File Editor (See chapter 11.3.12 for further information.).

Calibration gas concentration

Disable calibration levels

Adding com-ponents /levels


11.3.9 Validation setup Menu bar Parameter Validation setup


Here you can configure all parameters for auto-validations.

The validation setup is described in chapter 9.5.


11.3.10 Analog output configuration

Menu bar

Parameters Analog output conf.

If you have a board with 4, 8 or 16 analog outputs in your analyzer, you can

edit the configuration and correlation between outputs and results in this

window.

How to configure the output signals

Only that number of channels is editable which are present.

1. Select the mode of the desired output type under „Analog output type“.

The resolution of the voltage outputs is 1.22mV and the resolution of the

current outputs is 2.7µA.

2. Select for every channel a component from the results file of the

chromatography software (Drop-down menu).

3. Edit the low and high range values.


following results:

• All analog outputs (4) got the type 0-10V.

• Channel 1: It shows the result for benzene.

The output voltage of channel 1 will range linear between 0V for 0ppb

benzene und 10V for 10ppb benzene.

• Channel 2:

It shows equivalent 0V for 5ppb toluene und 10V for 100ppb toluene.

The same is valid for the channels 3, 4 and 5 for the other components.

The channels 6 to 8 will not be used.


Fig.5: Connection of analog outputs

11.3.11 Alarm configuration

Menu bar

Parameters Alarm config.

If you have a board with digital outputs in your analyzer, you can edit the

configuration of the four alarm outputs in this window.

1. Select the components from the calibration file in the drop-down list. You

can configure several alarms for one component.

2. Select the type of alarm (high alarm or low alarm) for each output.

3. Edit the alarm threshold for each output.

Note: This concentration must be exceeded / under-run to activate the

alarm. If the alarm threshold is 5 ppb and the measurement value is 5

ppb, then the alarm is not activated.



following results:

• Alarm 1 is activated when the concentration of benzene exceeds 5 ppb.

• Alarm 2 is activated when the concentration of benzene exceeds 10

ppb.

• Alarm 3 is activated when the concentration of toluene exceeds 20 ppb.

• Alarm 4 is activated when the concentration of m,p-xylene under-runs 1

ppb.

Note

If you select a new Chrom Perfect method in the analysis parameter

window, all alarms are set to the first component, high alarm and 0 alarm

threshold for security reasons.

11.3.12 CP Analysis

Menu bar Parameter CP Analysis

You can start the Chrom Perfect Analysis module with this menu item. In

the Analysis module saved chromatograms can be viewed or evaluated.

You can also change the integration parameters or modify the retention

time windows. See chapters 7.2 – 7.4 for detailed information.

Note

Before starting the CP Analysis or CP File Editor the menu item “Unlock” in

the menu bar has to be activated. Otherwise these menu items are

disabled.


11.3.13 CP File Editor

With the CP file editor we can modify Chrom Perfect method files and

calibration files.

Note

Before starting the CP File Editor or CP Analysis the menu item “Unlock” in

the menu bar has to be activated. Otherwise these menu items are

disabled.

Menu bar Parameter CP File Editor

1. Start the Chrom Perfect File Editor by selecting this menu item.

The following windows pops up:

2. For editing a method click on the left upper button, for editing a

calibration file click on the right upper button to open a corresponding

file.

3. The other file types are not needed.

How to edit method files, see next pages.



Press the button Method file (MET)

The window below pops up:

Method (.MET) files contain directions for acquiring data and processing

chromatogram files (.RAW).

In the following chapter the different configurations of each tab (as

displayed below) are described.

Acquisition tab:

On this tab you can configure

o the length of a chromatogram (Run time)

o the recording frequency (Data samples per second)

o the limits of the standard view of the real time plot (high scale, low

scale).

Events tab:

On this tab you can set integration events.

This can be easier done in the Analysis module (see chapter 7.4).

These parameters are preconfigured by AMA Instruments as well.

How to edit method files


Processing tab:

On this tab you can configure

o the peak detect threshold

o the minimum peak width

o the calibration file to use.

Definition of the peak detection threshold:

The Initial peak detection threshold tells the peak-detection algorithm how

much noise may be expected in the chromatogram. This number is

dimensionless. Appropriate values range from -6 to +28:

• If the value is too large, then peaks will be treated as noise, and missed.

• If the value is too small, then noise will be treated as peaks, and the

chromatogram will be littered with false peaks.

How to determine the threshold:

1. Select context menu measure noise

in a real time plot or a loaded chromatogram.

The program will tell you the noise and the recommended threshold.


Report tab:

On this tab you can specify reports which shall be created.

Note

This part has been already configured by AMA Instruments. Do not modify

or delete these two files: last_results2.fmt and results.fmt. They are

necessary for a working data transfer to the GC 5000 software!

Plot tab:

On this tab you can set the limits of the standard view when loading a

chromatogram in the Analysis module.


Plot options tab:

On this tab you can configure which details you want to see in a real time

plot or in a printed chromatogram.



press the button Calibration file (CAL)

Calibration files contain the information to identify components and to

calculate their concentrations.

Component tab:

Calibration file (CAL) Component tab:

The spreadsheet at the top of the window displays the component

information, one row for each component:

• The column called “component name” contains the name that appears

in plots and reports. Every component has to be identified with a well-

defined name, i.e. the name must be unique.

• The columns called “Retention time, Window width, Reference

component” determine the interval of retention time. This interval

identifies a peak as the relevant component. Every component must

have an unique retention time.

Example: If the retention time is 12 minutes and the window width is

one minute, then the peak may elute anywhere between 11

and 13 minutes.

How to prevent that a component's retention time changes during an

update:

double-right-click on the retention time cell

to toggle the cell of the update status to the frozen status. The

background color of the cell turns red when changing in the frozen

status.

• The column “ref. comp.# ” you can select a reference component. Then

the retention window of the component is shifted according to a

retention time shift of the reference peak.

How to edit calibration files


• The column “Fit Type” specifies the kind of calibration curve that will be

fitted to the data points. The column “Origin” specifies whether the

calibration curve will ignore the origin, or it will be forced to pass through

the origin, or it will be extrapolated to the origin.

The “fit type and origin settings” together determine the number of

distinct (not replicate) data points that must be present. This table

shows the minimum number or data points required for each choice of

fit type and origin.

Type of fit Ignore or Extrap Zero Force Zero

Point-to-point (PTP) N/A 1

Linear 2 1

Quadratic (Quad) 3 2

Cubic 4 3

Power N/A 2

• The column called “Quant” (quantification) determines which peak

property is taken as the source of the data points. The parameter are

height, area, multipeak height, and multipeak area.

Note: The first two parameters height and area are the most frequently

used. Area usually gives more reproducible results than height for well-

resolved peaks. However, when peak separation is poor, “height” can be

more accurate than “area”.

Special case of quantification:

The two other quantification types - multipeak area and multipeak height

- base the response on the sum of the areas or heights of all of the

peaks that fall within the component’s search window.

Note: These types of quantification are useful in aggregate hydrocarbon

analysis when you want the sum of all peaks in a window.

• The columns “Level amount” and “Level Response” occur in pairs,

one for each level in the calibration file.

.


We now turn to the control buttons below the spreadsheet.

• The two radio buttons (“external / internal standard) determine

whether the calibration file will use external or internal calibration.

The GC 5000 BTX will always use external calibration.

• The Default Component list box determines which component, if

any, will be used to quantify peaks that are not identified as

components.

There are three possibilities:

1. Increase the number of components:

Select a component (row) and press the “Insert Comp button”.

Each press will generate a new row after the selected row.

The contents of the selected row will be copied into the new row, except

for the component name, which will read "[New]".

2. Insert a component before the first row:

Select the upper left corner of the spreadsheet instead of a row.

In this case, the new entries will be blank.

3. Remove a component:

Select it and press the “Delete Comp button”.

The selected row will vanish.

There are three possibilities:

1. Increase the number of levels:

Select an existing level (either column) and press the “Insert Level

button”.

Each press will generate a new level (two columns) after the selected

level. The contents of the new level will be zero.

2. Insert a level before the first level:

Select any non-level column.

3. Remove a level:

Select it and press the “Delete Level button”.

The selected column pair will vanish.

How to copy the contents of one cell to those below it:

Select a block of cells and press the “Copy Down button”.

How to change a number of components

How to change a number of levels

Copy


Calibration file (CAL) Misc options tab:

Signification of the boxes in the window above:

• “Creator” and “Description” boxes

are for documentation purposes only. These fields normally contain the

developer's name and the description of the method. They will appear

on the printout, but have no other effect.

• “Area reject value“

determines a minimum peak area. Peaks with less than this area will be

omitted from the report. If the plot shows baselines, such peaks will

have a baseline, but not the retention time or other peak labels.

• “Reference peak area reject”

It determines a minimum peak area for a reference peak. Peaks with

less than this area will not be used as retention time references.

If a peak of a reference component fails to meet this threshold, it will not

be used as reference peak. Then the retention time windows of the

depending components will remain in their original positions.

• “Amount units” box

Its content may be printed on formatted reports, but does not affect the

numeric values.

• “Weighting method for averaging”

This radio button must be set to “Equal weight for all updates” as this

is necessary for a correct averaging. Otherwise the result after a

calibration with more than two runs per calibration level is not as

expected.


Calibration file (CAL) Misc options tab Perform an update:


How to process new calibration data subsequently from an already

acquired chromatogram:

The relevant data input is displayed in the window above.

1. Specify the correct calibration level in the field „Level to update“.

2. Select one the three radio buttons on the left which determine the type

of update.

3. Click on one of the two radio buttons on the right. Select whether the

new data shall be used or whether the old and the new data shall be

averaged.

4. Select the name of the corresponding chromatogram in the field „Bound

File Name”.

5. Click onto „OK“.

The data has been produced.

6. Select Component tab

On this tab you can check the new retention times and/or the new

response values.

7. At last the component table shall be saved again by

clicking Menu item File Save

The data has been saved.

11.3.14 Module setup

Menu bar Parameter Module setup

In this menu you can configure connected AMA Instruments modules like a

sample stream selector, a dilution module or a permeation module.

The module setup is described in detail in chapter 9.2.3.

Subsequent calibration


11.4 Program steps

11.4.1 Standard BTX

Menu bar Program steps

All program steps of the analyzer can be checked up here. It requires that

the sample program has already been stopped.

Program steps:

• Program stopped

• Purging of sample line

• Sampling

• Waiting for GC Ready

• Injection

• Waiting for end of cycle time

If the sample program is running, this menu item is disabled.

In this case the current program step is always shown real-time on the

monitor.

Program stopped


Purging of sample line

Sampling

Waiting for GC Ready


Injection

Waiting for end of cycle time


11.4.2 BTX with stripper column

Menu bar Program steps

All program steps of the analyzer can be checked up here. It requires that

the sample program has already been stopped.

Program steps:

• Program stopped

• Purging of sample line

• Sampling

• Waiting for GC Ready

• Injection

• Waiting for end of cycle time

If the sample program is running, this menu item is disabled.

In this case the current program step is always shown real-time on the

monitor.

Program stopped


Purging of sample line

Sampling

Waiting for GC Ready


Injection

Waiting for end of cycle time


11.5 View Menu bar View

It displays the following menu items:

• Events

• Last results

• Result table

• Validation status

• GC oven program.

Menu bar View Events

Every event of interest will be saved in the event.log file with date and

time.

For example:

• Alarms like FID flame off, carrier gas pressure below minimum, power

failure etc.

• The reset of alarms as described above.

• Standard events like cycle start or program Stop.

Use the menu items

to save

or to print

or to clear the event.log file.

Events


Menu bar View Last results

This window displays the results of the last cycle.

Menu bar View Results

This window displays the results of all cycles.

Last results

Result Table


Menu bar View Events

This window displays the current validation status.

In this example every check is within the defined limits.

o Green indicates that the validation run of all tests is ok.

o Yellow indicates that the warning level has been reached

o Red indicates that the error level has been reached.

(See page 59-60 for further information about warning and error levels

and the different types of validation tests.)

Menu bar View GC Oven Program

This window displays the diagram of the GC oven program and its current

status:

It displays

if the GC oven program is running

the current GC oven temperature

the remaining time for the current temperature program.

It displays the GC ready status:

If the status is not ready (status field color is yellow or red), then click on the

status field for detailed information.

GC oven program

Validation status


11.6 Run calibration (manual and auto-calibration)

Menu bar Run Calibration

With the help of this menu item you can start a manual or automatic

calibration.

Note: The standard sample program has to be stopped first.

Menu bar Run Calibration Manual Calibration

This menu item enables to start a manual calibration of only one calibration

level.

1. Select one calibration level of the list.


2. Select the number of runs for this calibration level

3. If the result of the first run is to be discarded mark that check box.

4. Press ok.

In this example the level is calibrated with the average value from the

2nd and 3rd run.

Without a calibration module or built-in calibration valves, this is the

possibility to run an auto-calibration. Only the connection of the calibration

gas to the sample port has to be done manually:

Menu bar Run Calibration Manual Calibration Sequence

1. Before each 1st run of a calibration level, you are asked to connect the

correct calibration gas to the sample port and then press Start.

2. After the analyzer did the number of runs it asks you to connect the next

calibration gas to the sample port and press Start again.

Manual calibration

Manual calibration sequence


Note

The items like “number of runs per level” and “if to discard the results of the

first run” is configured in Menu bar Parameter Calibration

Calibration setup (See chapter 11.3.8)

Menu bar Run Calibration Auto-Calibration

Here you can start a fully automatic calibration for all calibration levels at

once.

After the analyzer did the number of runs it automatically switches to the

calibration gas for the next level and does the next runs. The analyzer stops

after the runs for the last calibration level.

This function is only enabled if

• you have built-in calibration gas valves and only two calibration levels

• or an external calibration gas module with up to 20 calibration levels.

Calibration setup:

Menu bar Parameters Calibration Calibration setup

The number of runs per level and if to discard the results of the first run is

configured in the calibrations setup. (See chapter 11.3.8 for detailed

information).

Auto-calibration


11.7 Run validation

The definition of a validation and the validation setup are described in

chapter 9.5.

Note: The analyzer has to be stopped before starting a validation with this

menu.

These menu items are only enabled if

• you have built-in calibration gas valves or

• an external calibration gas module


Here you can start an initial validation.

You have to do an initial validation after a new calibration or when you

changed the validation gas.

After selecting this menu item the analyzer starts to do the initial validation.

The analyzer stops after the run is completed.

Menu bar Run validation Standard validation

Here you can start a standard validation.

After you have selected this menu item the analyzer starts to do the

standard validation. The analyzer stops after the run is completed.

Menu bar Run validation Test Level or input

Here you can start a test sample of a calibration level when using a

calibration module or an input when using calibration valves.

The analyzer stops after the run is completed.

Initial validation

Test

Standard validation

General


11.8 Help functions

11.8.1 Remote support

Clicking onto “Remote support” will start the AMA Remote Support utility.

Then AMA Instruments service engineers can connect to the analyzer via

Internet and can help you by remote maintenance:

1. Tell us the ID and

2. the password.

11.8.2 About

Clicking “About” will inform you about the running software version. This is

useful if you have any questions.

How to get connected:


12 Miscellaneous procedures

12.1 Programming and editing values

1. Select

Menu bar Parameters

2. Click on the input field of the parameter which has to be modified.

3. Enter the new value by keyboard or by clicking the corresponding

buttons on the numeric input window.

4. Select Menu bar save as actual values

The new parameters are saved as current values in case no errors are

detected. (See chapter 11.3.6).

Before the new parameters are accepted as new working parameters,

they will be checked automatically by the system.

The system indicates an error message in case parameters are not

allowed.

In general all parameters can be changed at every time and in every

program step.

The following points have to be noticed if you need to change parameters

when the sample program is running.

It is not possible to change the time for an already running program step. In

this case the new time value will get active in the next cycle.

Example:

The program step “sampling” is running and the value for the sampling time

has been changed and saved as current value.

Effect:

The sampling will end with the old value of the sampling time. But in the

next cycle the sampling will get started with the new sampling time.

The maximum for each program step is: 59 min 59 sec.

The maximum for the cycle time is: 23h 59 min und 59 sec.

New temperature set points will be accepted immediately and independent

from the current program step.

Change of parameters in general

Change of parameters during program run:

Change of time set points

Change of temperature set points


12.2 Programming GC oven parameters

12.2.1 How to display the running temperature program:

1. Select Menu bar Parameters GC oven

An initial temperature below + 40°C is not possible.

The heating rates have to range between 0°C/min and 25°C/min.

Every final temperature has to be equal or higher than its start temperature.

No temperature value is allowed to exceed +210°C.

Setting a temperature rate to zero means the temperature program will end

at this point and the following parameters will be ignored.


12.2.2 Selection of the parameters for the running temperature

program:

In this field, the value of the initial temperature has to be selected. It has to

be between +40°C and +210°C. Otherwise an error message will occur.

During this time the GC oven temperature is kept on the level of the initial

temperature.

In this field the selection of the heating rate for the first phase of the

temperature program is possible. It has to range between 0°C/min and

+25°C/min.

This means the end temperature of the first heating ramp. It is

simultaneously the starting temperature for the second phase of the

temperature program.

During this time the GC oven temperature is kept on the level of the final

temperature 1. This can be the final temperature of the program (heating

rate 2 = 0) or the base temperature of the next heating phase.

In this field the selection of the heating rate for the second phase of the

temperature program is possible. It has to range between 0°C/min and

+25°C/min.

This means the end temperature of the second heating ramp. It is

simultaneously the starting temperature for the third phase of the

temperature program.

During this time the GC oven temperature is kept on the level of final

temperature 2. This can be the final temperature of the program (heating

rate 3 = 0) or the base temperature of the next heating phase.

In this field the selection of the heating rate for the third and last phase of

the temperature program is possible. It has to range between 0°C/min and

+25°C/min.

This means the end temperature of the third and last heating ramp.

During this time the GC oven temperature is kept on the level of final

temperature 3. This is the final temperature of the program. In the following

step the GC oven is cooled down to the initial temperature.

The total time for the GC oven temperature program is the addition of all

isotherm and heating times. This value will be updated after pressing the

“calculate” button.

Initial temperature

Initial time

Heating rate 1

Final temperature 1 1 temperature

Final time 1 temperature

Heating rate 2

Final temperature 2

Final time 2

Heating rate 3

Final temp. 3

Final time 3

Total time of GC oven


12.3 Start and stop

How to start a program cycle:

1. Start a program cycle by pressing the “Start” button in the main window.

Then a small window pops up:

2. If you click ok, the cycle starts immediately.

or

3. If you check “Set time for start” a new input area pops up:

4. Enter the time for the start in the 24 hours format, i.e. 18 o’clock means

6 o’clock pm.

The analyzer waits until this time and starts the cycle automatically.


How to stop a running program step:

1. Press the “Stop” button in the main window, if the program is running

and you want to stop it.

Then a small window pops up:

2. If you press OK the program stops immediately.

or

3. If you select “Stop when analysis is completed” the analyzer continues

completing data acquisition of this chromatogram.

One minute later the analyzer stops.


12.4 Subsequent data processing

You can adjust integration parameters and/or retention windows in case a

recorded chromatogram have not been integrated properly (as described in

the chapters 7.2 and 7.4). Furthermore you can reprocess already acquired

chromatograms again.

How to process already acquired chromatograms:

1. Use the Chrom Perfect module „Data Acquisition“ which gets

automatically started by the GC-5000 controlling software.

2. Select „Instrument Control“ in the context menu on the lower half of

the window.

In the new window click onto the button „Change Download“.

Then the following window pops up:

On the tab „Finished Jobs“ the last recorded chromatograms are listed.

1. Mark the chromatograms which shall be analyzed and click onto the

button Create Sequence file from selected entries

2. Save the sequence file under any name.

3. Menu bar Parameters CP Analysis

Start CP Analysis and load any chromatogram.


4. Menu bar Tools Batch process

Select „Batch Process“ in the „Tools“ menu and the following window

pops up:

5. Check that the radio button of „Sequence File“ is marked and press

„OK“.

6. In the next window select the sequence file which you created before

and click onto „OK“.

The next window displays a list of chromatogram files:

7. Press “OK” and the sequence is automatically worked off and a table

with the results (c:\cpdata\gc5000\results.txt) is created.

Is the table already present, then the new results are appended to the end

of the old file.

With menu bar view results table, the results will be displayed as well

in the GC 5000 Software.


Optionally:

When you double-click onto the traffic light symbol which appeared in the

notification area of the PC, a new window pops up in which you can see the

progress of the batch processing:


13 Maintenance

13.1 Security instructions

Warning!


physical injury or damage to property. Disconnect the GC 5000 from the

power supply before starting with maintenance.

Warning!

The enrichment tube is normally heated to 230°C (up to 300°C). Disregard

may result in third-degree-burns. Wait until the tube has cooled down!

Caution!

There can be a wrong temperature measurement because of different

electrical potential. Avoid direct contact between the thermocouples and

metal parts.

Warning!

During the exchange of the rotary valve, the unit has to be switched on as

the valve has to be turned. Electrical parts apply hazardous voltage while in

use. Only qualified, accredited technicians in the field of electricity are

permitted to exchange the rotor.

Warning!

The valve oven heater is normally heated up to 80°C (max. 150°C).

Disregard may result in third-degree-burns. Adjust the valve oven

temperature to 40°C and wait until the heater has cooled down to 40°C


13.2 Maintenance schedule

On a preventive maintenance basis we recommend to replace the following

components at regular intervals.

Maintenance work shall only be done by AMA Instruments or by authorized

maintenance personnel, i.e. authorized for maintaining and repairing this

kind of systems and electrical circuits in accordance with accepted

technical safety standards.

Component Yearly Every two

years

Back panel fan

x

BTX enrichment tube

x

Fan of the Peltier cooler

x

GC column

x

GC oven motor

x

Inlet filter for MFC

x

Maintenance kit FID (FID jet, sealings)

x

Maintenance kit PID (lamp, centering ring, sealing)

x

Pump

x

Rotor of the rotary valve

x


13.3 Maintenance work

13.3.1 Exchange the enrichment tube

Warning!

The enrichment tube is normally heated to 230°C (up to 300°C). Disregard

may result in third-degree-burns. Wait until the tube has cooled down!

How to remove the old tube and mount the new one:

1. Disconnect the thermocouple plug of the enrichment tube.

2. Close the carrier gas.

3. Remove the PVC cover of the Peltier cooler.

4. Demount the 1/8” nuts on both sides of the enrichment tube and

loosen the brass nuts on the ceramic isolators.

5. Remove the four screws and the aluminum top from the Peltier cooler.

6. Take the enrichment tube and the Teflon isolators out of the cooler.

7. Mount the new enrichment tube between the two fittings.

8. Adjust the tube exactly in the center of the cooler and the

thermocouple on top of the tube.

9. Tighten the brass nuts on the ceramic isolators.

10. Mount the aluminum top again.

11. Put the PVC cover onto the cooler again.

12. Plug in the thermocouple plug.

The new enrichment tube is inserted.

Fig. 7: Exploded view of the Peltier cooler of the enrichment tube


13.3.2 Maintenance of the pump

The built-in pump is absolutely maintenance free.

If the membrane is abraded (the flow rate will drop dramatically) the

complete pump has to be exchanged.

13.3.3 Exchange the input filter of the MFC

To protect the MFC from dust or other small particles a filter is mounted in

front of the MFC. Is the filter blocked, it has to be exchanged.

Exchange the filter:

1. Loosen the two fittings

2. Pull the filter out of its holder.

3. Put a new filter into the holder

4. Mount the two fittings again.


13.3.4 Exchange or repair the capillary column

Warning!



power supply before starting to exchange the capillary column.

Note

The column is fragile. Handle it very carefully and avoid hits while mounting

in. If you install an already used column, cut off the first 2 cm of this used

column. Cut it only with a suitable cutter (see fig. 8 and description on the

next page).

How to remove an old column:

1. Switch off the system, unplug the power cable

2. Open the cover.

3. Unlock the opening mechanism of the GC oven cover.

4. Pull the locking knob and draw the cover to the right.

5. Lift up the cover.

6. Loosen the 1/16” nuts at both ends of the capillary column (carefully!).

7. Take out the GC column.

8. Put the nuts and fused silica adapters onto the new column and check

the ends of the column whether they are blocked by something. (The

fused silica adapters are re-usable a lot of times.)

9. Cut off a short piece of the column, if the ends are not flat.

Fig.8

10. The column has to be pushed through the ferrule for 2-3mm.

11. The nuts have to be tightened until the column is not movable in the

ferrule anymore.

12. Mount the GC oven cover in reverse order as described above.

The new column is inserted.


How to prepare and cut a capillary column in the right way:

1. Cut the ends square with none of the polyimide coating projecting

beyond the ends.

2. Inspect the ends with a 20X magnifier to make sure the cut is square.

3. In case the end is not square, make a small scratch about 1-inch from

the end with a diamond-tipped or ceramic scriber.

4. Therefore hold the column between the thumb and the forefinger, one

hand on either side of the scratch.

5. Place the scratch away from you and apply slight pressure with your

thumbs.

The column should snap easily and cleanly.

Note: Avoid making any scratches elsewhere on the column as this can

cause your column to break.

How to repair a broken column by using a capillary column

connector:

Universal capillary connectors provide a convenient method to connect a

capillary column together without any introduction of dead volume or active

sites.

1. One end at a time, firmly press the end of each column into the opening

in the capillary column connector.

A complete and uniform ring should be visible where the polyimide of

the column is in contact with the glass from the fitting.

2. If not, remove the column, re-cut the column, and re-install.

A leak-tight connection is formed between the polyimide coating and

the fused silica connector.


13.3.5 Adjust the detector signal

Adjust the level of the detector base signal:

1. Turn the trimmer in the upper left corner of the detector amplifier case.

2. Adjust the base signal level after warm up of the system in such a way,

that the signal is <100mV when the detector is off and > 100mV when it

is on.

13.3.6 Check the glow plug

1. Pull the FID cover off the detector.

2. Remove the connector with the white cable from the glow plug.

3. Measure the electric resistance between the center pin of the glow plug

and the detector case. It should be less than 20Ω but more than 4Ω.

4. If the glow plug is broken, unscrew the glow plug and replace it.

5. Mount the electrical connector again without touching the case of the

glow plug.

Note

There must be a gap between the case of the glow plug and the electric

connector. Otherwise you will have a short circuit between both connections

of the glow plug and the ignition might not work.


13.3.7 Check the thermocouples

Warning!

Electric parts apply voltage while in use. Disregard may result in death,


power supply before starting to check the thermocouples.

Caution!

There can be a wrong temperature measurement because of different

electrical potential. Avoid direct contact between the thermocouples and

metal parts.

How to check the status of the thermocouples:

1. Unplug the thermocouple connector

2. Measure the electric resistance between both pins: It should be less

than 20Ω. Make sure that there is no connection to the analyzer case.

Thermocouple type J color coding:

IEC/CEI + black / - white

ANSI + white / - red

DIN + red / - blue

13.3.8 Check the heating units of detector and valve oven

Warning!



power supply before starting to check the heating units of the detector and

valve oven.

1. Unplug the heater connector.

2. Measure the electrical resistance between both pins: It should be

between 200Ω and 600Ω if it works properly.

3. Exchange the heating unit if the electrical resistance is indefinite high.


13.3.9 Exchange of the PID lamp

Warning!


physical injury or damage to property. Shut down and switch off the GC

5000 and disconnect it from the power supply before starting to exchange

the PID lamp.

Caution!

While removing, the PID lamp can fall out of the detector top. Lay a

particle-free wipe under the detector top outside of the analyzer and turn

the top around and do not hold it downwards.

Caution!

While removing the PID lamp, the window can get contaminated. This will

decrease the UV-intensity and reduce the lifetime of the PID lamp.

Therefore do not touch the PID lamp with fingers. Use a particle-free wipe.

1. Remove the top cover.

2. Disconnect the PID power cable (red/blue) from the PCB of the PID

top.

3. Remove the two milled screws from the detector top and pull it to the

left.

Attention: Do not hold the top downwards as the lamp can fall out of

the detector top.

4. Lay a particle-free wipe under the detector top outside of the analyzer

and turn the top around. The lamp slips out of the exciter coil.

5. Loosen the big PEEK nut on the PID bottom.

6. Pull out the Viton sealing with a forceps and replace it with a new one.

7. Tighten the PEEK nut again.

8. Take the PID top and put the new lamp into the exciter coil without

touching the lamp with the fingers.

9. Hold the PID top horizontally with the electric connector on the left side

and move it towards the PID bottom until the two brackets reach their

leadings.

10. Do not cant the movable part.

11. Mount the two milled screws again.

12. Connect the cable again.

The new PID lamp is inserted.


13.3.10 Clean the PID lamp window

1. Demount the PID as described in 13.3.9.

2. Use a particle-free wipe and dry methanol to clean the lamp window.

3. Mount the PID again as described in 13.3.9.

13.3.11 Exchange the rotor of the rotary valve

Warning!

During the exchange of the valve the GC 5000 has to be switched on as the

valve can be turned. Electrical parts apply hazardous voltage while in use.

Only qualified and accredited technicians in the field of electricity are

permitted to exchange the rotor.

Warning!

The valve oven heater is normally heated up to 80°C (max. 150°C).

Disregard may result in third-degree-burns. Adjust the valve oven

temperature to 40°C and wait until the heater has cooled down to 40°C

Fig. 8: Exploded view of the rotary

valve


How to exchange the rotor of the rotary valve:

1. Turn off the carrier gas supply but let the GC 5000 switched on.

2. Remove the cover of the valve oven.

3. Loosen the set screw in the heater of the valve (Caution, hot!) and

pull the heater off the valve.

4. Unscrew the entire knurled preload assembly

as shown in the figure aside. Note: Do not

tamper with the preset socket adjustment

screw.

5. Engage the end of the rotor with a pencil-type magnet.

6. After the valve is switched once (Program steps, Enrichment,

Sampling) the rotor can be taken out.

7. Put a new rotor in.

8. Take care that the ID letter E on the rotor tab

is directed toward port 4 of the valve.

(port 4 is marked with an arrow, see fig. aside)

9. Turn the preload assembly into the valve body again by hand just

beyond the point where it touches the rotor.

10. Cycle the valve 10 times (Program steps, Enrichment, Sampling

respectively Program stopped).

11. Tighten the preload assembly in quarter-turn increments, cycling the

valve 10 times after each step.

12. Repeat this step until the preload assembly cannot be tightened

anymore by hand.

13. Install the heater again and fix it with the set screw.

14. Mount the valve oven cover.

The new rotor is inserted.


13.3.12 Exchange the GC oven motor

Note

The column is very fragile. Handle it carefully and avoid hits while operating

in the GC oven.

1. Switch off the system, unplug the power cable and open the cover.

2. Unlock the opening mechanism of the GC oven cover.

3. Pull the locking knob and draw the cover to the right.

4. Now you can lift up the cover.

5. Loosen the 1/16” nuts at both ends of the capillary column (carefully!).

6. Then take out the GC column.

7. Now remove the bottom cover of the analyzer and lay the analyzer

onto the side.

8. Demount the four cap nuts which hold the oven sheet and put it

upright.

9. Take care that the temperature sensor and the gas line from the

detector are not damaged.

10. Remove the nut from the oven fan (left-hand thread)

11. Take out the fan wheel.

12. Demount the snap ring from the axis of the motor.

13. Pull off the three cables from the motor on the bottom side of the

analyzer.

14. After the removal of the three screws you can take out the motor from

the analyzer.

The motor is dismounted.

Install the new motor in exact the reverse order as you have it

dismounted.

13.3.13 Exchange the back panel fan

1. Unplug the power cable of the fan.

2. Remove the four nuts.

3. Take out the old fan and put in a new one.

4. Mount the four nuts again and plug in the power cable of the fan.

The back panel fan is exchanged now.


13.3.14 Exchange the Peltier cooler fan

1. Close the carrier gas supply.

2. Remove the PVC cover.

3. Unplug the thermocouple plug of the enrichment tube.

4. Disconnect the power cable of the Peltier cooler.

5. Demount the 1/8” nuts on both sides of the enrichment tube.

6. Loosen the brass nuts on the ceramic isolators.

7. Demount the hexagonal screw which fixes the cooler in its case.

8. Take the cooler out of the case.

9. Remove the two screws of the fan.

10. Unsolder the two wires of the fan. (Notice the orientation of the

wires!) (You can demount the four plastic distance bolts to simplify the

access to the bottom side of the PCB.).

11. Solder in the two wires of the new fan in the same orientation as with

the old fan.

12. Mount the fan on the heat sink with the two screws.

13. Put the cooler into the case and fix it with the hexagonal screw.

14. Mount the 1/8” nuts on both sides of the enrichment tube.

15. Tighten the brass nuts on the ceramic isolators.

16. Connect the power cable of the cooler.

17. Plug in the thermocouple plug of the enrichment tube.

18. Put on the PVC cover.

The new Peltier cooler fan is inserted now.

13.3.15 FID maintenance

Caution!

While inserting the new FID jet, it can get contaminated. This will decrease

the measurement signal or cause noise and a high baseline. Therefore do

not touch the FID jet with your fingers, use a pair of tweezers or pliers.

1. Pull the FID cover off the detector.

2. Unplug the two cables of the FID.

3. Remove the six screws of the FID top.

4. Remove the FID top. Loosen the nut of the FID jet.

5. Pull out the old FID jet.

6. Insert the new FID jet with pliers or a pair of tweezers. (Do not touch it

with your fingers!).

7. Exchange the Teflon O-ring seal.

8. Put the FID top in and mount it with the six screws again.

9. Plug in the two cables.

10. Put on the FID cover.

The new FID jet is inserted.


14 Troubleshooting

This chapter refers mainly to service technician and maintenance personnel. 1. The list below shows general faults and how to correct them. 2. In case of a system breakdown the user will be informed by automatically displayed message boxes. It can be either an alarm, error or a warning message. All types of these messages are listed in this chapter.

Note

Faults Refers mainly to general problems of wear parts.

Warning Advices to a small inconsistency in the program.

Alarm Advices to program errors.

Errors Refer to serious hardware problems within the analyzer; contact

AMA Instruments for maintenance as errors are not serviceable

by the user.

14.1 General faults

The list below refers mainly to general problems. The repair should be done by authorized trained personnel, respectively service technician.

Fault Cause Detect and Repair

Enrichment tube is

not heating

1. Fuse is broken Check the corresponding fuses in the

electronic control board.

2. The electrical connections from

transformer to the tube holder

are loosen or corroded.

Clean cable eyes with fine sandpaper

and mount them tight.

3. The heater transformer is

broken.

1. Check: Voltage between the two

fittings of the enrichment tube shall

be about 2.2V AC.

2. If the voltage is not present, the hea-

ting transformer has to be replaced.

4. Thermocouple is broken and all

heaters have been switched off.

Software error 10: Refer to status or

event log

Valve oven, GC

oven or detector is

not heating

1. Fuse is broken. Check the corresponding fuses in the

electronic control unit.

2. Carrier gas pressure is below

minimum

Check the carrier gas supply.

3. The heater element is broken Exchange heater element.

4. Thermocouple is broken and all

heaters have to be switched off.

Software error: 7,8 or 9: refer to status or

event log.


Fault Cause Detect and Repair

No peaks in

chromatogram

1. FID is not ignited 1. Check for condensing water with a mirror

at the FID exhaust.

Result: If there is no condensing water, the

FID flame is not burning.

2. Adjust the detector signal properly as

described in chapter 13.3.5

2. FID is contaminated 1. Switch off the analyzer and let the FID

cool down.

2. Remove the upper part of the FID by

loosening the hexagon socket screw on

the upper side of the FID with a 1.5 mm

Allen Wench.

3. Look into the FID, check whether there

are any particles or dirt on the FID jet or

on the electrode.

4. Clean FID jet and/or electrode if

necessary.

3. The 6-port valve is not

switching

Check if 6-port valve is switching properly:

1. By clicking “Program steps”,

“Enrichment”,

“Sampling” and

2. By clicking “Program steps”,

“Enrichment”, “Program stopped” to

switch it back.

If the valve is not switching at all:

3. Loosen the rotor until the valve switches

properly.

4. Tighten it again as described in chapter

13.3.11.

Missing peaks or

many 0.0000 in

results file or last

result list

Method (btx.met) and /or calibration file

(btx.cal) have not been saved after

modification.

1. Save method and/or calibration file after

modifications.

“Chrom Perfect”

software does not get

connected to its

hardware (Status:

“offline in Chrom

Perfect”)

1. The serial connection

between PC board and

Lawson board is interrupted.

Check the cable.

2. The power line to the Lawson

Board has been interrupted.

Check the according cable.

Touch screen monitor

stays black

1. Software break-down of the monitor Switch off the monitor with the remote

control (green button) and switch it on again

with the remote control.

2. The power line of the monitor has

been interrupted

Check the according cable.


14.2 Alarm messages

There are seven different alarm messages which are automatically

displayed as a message box on the screen in case of a system break-

down; it advices to program errors.

The repair should be done only by authorized trained personnel,

respectively service technician who is able to read the English manual.

Type of Alarm Cause Detect and Repair

Alarm 1:

“The selected

sampling volume

has not been

reached 3 times

in a row. Program has

been stopped”

1. The pump or membrane

is broken.

1. Disconnect the outlet tubing from MFC

2. Check whether the pump is sucking properly

or not.

3. Exchange the pump if it sucks only weakly.

2. The rotary valve VE 1 is

not switching properly

and stays in a middle

position when switched.

1. Check the rotary valve VE1.

2. If necessary loosen the rotor until the valve is

switching properly.

3. Tighten it again as described in chapter 13.3.11.

3. The sample way is

permanently blocked

because the sample line

is blocked.

1. Disconnect the tubing from the sample inlet at

the back of the analyzer.

2. Start sampling and check the sample flow.

Result 3:

If it is ok now, then the fault is located in the sample

line:

Clean the sample line and remove any particles

which are blocking it.


permanently blocked

because of the MFC

If the flow is still too small (as described above in

step 1.-2.), then continue as follows:

3. Disconnect the inlet tubing from the MFC.

4. Start the sampling

5. Check if the sample flow is ok now.

Result 4 :

If the sample is still too low, the MFC has to be

maintained by the manufacturer AMA Instruments.


permanently blocked

because the in-line filter

is almost blocked.

If the flow is ok after disconnecting the tubing like

described above in step 1.-5. continue as follows:

6. Connect the inlet tubing of the MFC again

7. Disconnect the inlet tubing from the in-line filter.

8. Start sampling and check if the sample flow is ok.

Result 5:

If the sample is too small, the in-line filter has to be

replaced.



Alarm 1:

“The selected

sampling volume

has not been

reached 3 times

in a row. Program has

been stopped


permanently blocked

because the enrich-

ment tube is blocked.

If the flow is ok after disconnecting the tubing like

(described above in the steps 6.-8.) continue as

follows:

9. Connect the inlet tubing of the filter again.

10. Disconnect the inlet tubing of the enrichment tube.

(The tubing which is coated with Teflon hose and

directed to the right side of the analyzer).

11. Start sampling and check if the sample flow is ok.

Result 6: If the sample flow is still too small, replace the

enrichment tube.


permanently blocked

because the inlet

tubing of the enrich-

ment tube is blocked

If the sample flow described in step 11 is ok, then

continue as follows:

12. Blow with compressed air into the disconnected

tubing.

Result 7: This should clean the tubing.

If you get this problem with the blocked gas line again:

13. Connect a filter to the sample inlet to avoid it.

Alarm 2:

“The carrier gas

pressure is below

minimum! The

program has stopped”

The carrier gas bottle is

empty.

1. Exchange the carrier gas cylinder.

Alarm 3:

“The PID lamp is off.

The program has

stopped”

1. The lifetime cycle

of the UV lamp has

expired.

1. The PID lamp has to be exchanged.

2. The PID lamp is on

but the signal is still

below 100 mV.

1. Disconnect the PID power cable (red/blue) while

analyzer is running.

2. Check if the detector signal changes.

3. If yes, adjust the detector signal on the detector

amplifier as described in chapter 13.3.5.

Result: The signal in the main menu has to be

> 100 mV when the PID lamp is on.

When the PID lamp is off, the signal has to be

< 100 mV.



Alarm 5:

“The ignition of the

FID is not possible.

The program has

been stopped!”

1. The gas flows are

not adjusted properly.

1. Measure the gas flows at the corresponding needle

valve (air) or at the 1/16” hose in the GC oven

(make-up) and check whether :

- the air flow is 240 ml/min.

- the make-up gas is 30 ml/min

The hydrogen flow is controlled by a mass flow

controller and the current flow will be shown in the

AMA control software.

At the start-up there is often air in the hydrogen line

and it needs some time for the hydrogen to reach the

analyzer:

2. In this case, open he hydrogen line at the back of

the analyzer.

3. Let gas escape out of the line for about 5 seconds.

Result: Gas flow is normal; FID ignites

2. The glow plug is

broken.

1. Remove the connector from the glow plug.

2. Measure the electric resistance between the center

pin of the glow plug and the detector case. It should

be less than 20Ω but more than 4Ω .

Result: If the resistance is indefinite high or zero,

exchange the glow plug.

3. The FID is ignited but

the FID signal is still

below 100 mV. This may

be caused by using a high

purity of synthetic air.

1. Press the ignition button.

2. Check if the signal is higher than before but still

below 100 mV.

3. In this case adjust the FID signal-offset at the FID

amplifier.


> 100 mV when the FID flame is lit. In case the

flame does not lit, the signal has to be

< 100 mV.

Alternatively check if there is condensing water at the

FID exhaust:

1. Press the ignition button.

2. Check for condensing water with a mirror at the FID

exhaust.

3. If you see condensing water, adjust the FID signal

offset on the FID amplifier.


> 100 mV when the FID flame is lit. In case the

flame does not lit, the signal has to be

< 100 mV.



Alarm 5:

“ The ignition of the

FID is not possible.

The program has

been stopped!”

The FID is contaminated. 1. Switch off the analyzer and let the FID cool down.

(takes about 20 minutes)

2. Remove the upper part of the FID by loosening the

hexagon socket screw on the upper side of the FID

with an 1.5 mm Allen wrench.

3. Look into the FID, check whether there are any

particles or dirt on the FID jet or on the electrode.

4. Clean the FID jet and/or electrode.

Alarm 6:

“The temperature

of the FID is below

minimum.”

If the program is

running, it will be

stopped after time

out”.

The analyzer has just been

switched on and the detector

temperature has not yet

reached the set point. Wait

until the temperature has

reached it. This takes less

than 8 minutes.

Alarm 7:

“The temperature

of the FID has been

below minimum for

at least 8 minutes.”

The program has

been stopped!”

The heating element of the

FID is broken.

1. Switch off the analyzer

2. Pull out the white connector of the FID heater.

3. Measure the electric resistance of the heating

element: If it is not in a range of 200 to 300 Ω, the

heating element is broken.

4. Replace the heating element.

The fuse for the FID heating

unit is broken.

The fuse is placed on the SSR board at the bottom side

of the analyzer.

1. Switch off the analyzer

2. Contact the AMA service department (telephone

number: 0049 - 731/ 93321-00):

Our Service team will instruct you how to change

the fuse.

To avoid improper service, this manual does not describe exactly how to change the fuse as the AMA service department should be informed.


14.3 Warning messages

There are two different warnings which may occur.

A warning message advices to a small inconsistency in the program.

Type of Warning Cause Detect and Repair

Warning 1:

“ The enrichment

stage was not cold

enough at the start

of sampling. The

program will be

continued!”

The cycle time is too short. 1. Adjust the analysis parameters. (see chapter

11.3.6)

The ambient air is too high to

reach the enrichment

temperature.

1. Use an air condition system (down to 30°C is

required)

or

2. Increase the enrichment temperature value

(max. 40°C).

The fan of the Peltier cooler is

broken

1. Check if the fan wheel is still turning.

2. If not, replace the fan (see chapter 13.3.14)

The Peltier cooler is broken 1. Check if the coolers aluminum block is still cold.

(Do this during sampling or when the program is

stopped. The aluminum block can be warm during

injection or flushing and needs some time to cool

down).

2. If not, then replace the Peltier cooler.

Warning 2:

“The selected

sampling volume

has not been

reached. The

program will

be continued!”

The sample way was

temporarily blocked.

The pump could not suck the

desired volume through the

enrichment stage.

There are several reasons which may cause this

warning.

After getting this problem 3 times in a row, alarm 1 will

occur.

(See chapter 14.2 / Alarm 1 for analysis and repair of

the relevant problem).


14.4 Error messages

The GC 5000 BTX can show 8 different error messages which refer to

severe hardware errors within the analyzer.

Note!

Errors can be only maintained by the manufacturer. Therefore contact AMA

Instruments. Besides that first shut down the system and check the

communication cables. Disconnect the system from mains supply and

switch it on after 30 seconds.

Type of Error Cause Information

Error 1:

“Communication

breakdown to

temperature controller.

The program has been

stopped!”

Built-in computer gets no

connection to the temp-

erature controller.

This means that current temperature values are not

shown on the display anymore.

Heater set points cannot be changed.

Error 2:

“Communication

breakdown to valve

controller. The

program has been

stopped!”


connection to the valve

controller.

This means that current values for the carrier gas

pressure are not shown on the display anymore.

The valves are not switched anymore.

Error 7:

“Malfunction of the

detector temperature

sensor. The program

has been stopped!”

The temperature sensor is

broken.

All heaters are turned off.

Hydrogen supply is turned off.

The temperature sensor has to be exchanged.

Error 8:


GC oven temperature

sensor. The program

has been stopped!”


broken.




Error 9:


valve oven

temperature sensor.

The program has

been stopped!”


broken.




Error 10:


enrichment stage

temperature sensor.

The program has

been stopped!”


broken.



The enrichment tube has to be exchanged.


Type of Error Cause Information

Error 11:

“Communication

breakdown to sample

MFC. The program has

been stopped!”


connection to the sample

MFC.

This means that current sample flow values are not


The flow set points cannot be changed.

Error 13:

“Communication

breakdown to

hydrogen MFC. The

program has been

stopped!”


connection to the

hydrogen MFC.

This means that current hydrogen flow values are not


Flow set points cannot be changed.

15 Spare parts list

The list below contains the main components. They are necessary

for maintenance which will be performed on a preventive basis.

Component Art.-No

Back panel fan

1253

BTX enrichment tube

220

Fan of the Peltier cooler

131

GC column

1310

GC oven motor

1254

Inlet filter for MFC

427

Maintenance kit FID (FID jet, sealings)

10000

Maintenance kit PID (lamp, centering ring, sealing)

2013

Pump

526

Rotor of the rotary valve

242


16 Warranty

The warranty for the system lasts 12 month (referring to the date of

delivery).

1. The warranty covers only faulty material and workmanship. Repairs

necessitated by improper handling or improper transportation are not

subject to the warranty.

2. The warranty does not cover moveable parts and wear parts like the

Valco valve and the pump, commodities like adsorption tubes, glow

plugs etc.

3. The warranty requires appropriate handling and a periodic care to avoid

that the warranty claim expires, make sure that no kind of modifications

are made at the system.

4. Transportation: The customer bears the shipping costs one-way in case

of a delivery for repair within guarantee period. We recommend using

the original purpose-made packaging for a saver shipment of the unit.

Note!

In case of repair during warranty period, it is recommended to provide a

detailed and meaningful description of the failure in order to assure a fast

repair and to avoid a long-lasting defect analysis.


17 Gesytec-II protocol

17.1 Telegram Definitions All telegrams of the Gesytec-II protocol are listed below. Telegrams with the same identifications as in the Gesytec (Bayern-Hessen) protocol have partly different contents. Therefore you should always work with the complete documentation to avoid any confusion. For a better understanding in the following telegrams: Telegram control characters are enclosed in <> Binary data is symbolized by b BCC characters are enclosed in <> The BCC bytes are calculated by “exclusive or” of all bytes in front of the BCC bytes.

The representation ±±±±nnnn±±±±ee symbolizes the real value of the form:

sign: ± Mantissa, four-digit with implicit decimal point: 1.234

Sign of the exponent: ± Exponent, two-digit: 12. The digits are transferred as ASCII characters! Example: +1234-03 means +1.234*10-03

List of telegrams Status request MZ Status response ZM Data request DA Data response AD Control command ST Control response TS

17.2 Status request MZ

Telegram identification: MZ

Telegram length: Variable

Telegram type: Command

Brief description: Request the monitoring instrument status

Field no. Start byte Data format Field description

1 1 <STX> Start of text 2 2 b Length byte 3 3 MZ Telegram identification 4 5 b Monitoring instrument

identification (optional) 5 6 <ETX> End of text 6 7 <BCC1> Upper nibble 7 8 <BCC2> Lower nibble

If field number 4 is not present, the status of all monitoring instruments (components) is requested.


17.3 Status response ZM

Telegram identification: ZM


Telegram type: Response

Brief description: Status of the monitoring instruments as reply to MZ


1 1 <STX> Start of text 2 2 b Length byte 3 3 ZM Telegram identification 4 5 b Number of monitoring

instruments to transmit data 5 6 b Monitoring instrument ID

instrument 1 6 7 b Operating status 7 8 b Error status 8 9 b Serial number 9 10 b Monitoring instrument ID

instrument 2 (optional) 10 11 b Operating status 11 12 b Error status 12 13 b Serial number 13 14 b Monitoring instrument ID






instrument 8 (optional) 34 35 b Operating status 35 36 b Error status 36 37 b Serial number 37 38 <ETX> End of text 38 39 <BCC1> Upper nibble 39 40 <BCC2> Lower nibble


17.4 Data request DA

Telegram identification: DA



Brief description: Data request of the monitoring station


1 1 <STX> Start of text 2 2 b Length byte 3 3 DA Telegram identification 4 5 b Monitoring instrument

identification (optional) 5 6 <ETX> End of text 6 7 <BCC1> Upper nibble 7 8 <BCC2> Lower nibble

If field no. 4 is not present, the measured values of all monitoring instruments (components) are requested.

17.5 Data response AD

Telegram identification: AD

Telegram length: 20, 32, 44, 56, 68, 80, 92, 104, ...

Telegram type: response

Brief description: Output data of monitoring instruments as response to DA


1 1 <STX> Start of text 2 2 b Length byte 3 3 AD Telegram identification 4 5 b Number of monitoring


instrument 1 6 7 ±nnnn±ee Measured value

7 15 b Operating status 8 16 b Error status 9 17 b Serial number 10 18 b Monitoring instrument ID

instrument 2 (optional) 11 19 ±nnnn±ee Measured value



17 39 b Operating status 18 40 b Error status



19 41 b Serial number 20 42 b Monitoring instrument ID










42 99 b Operating status 43 100 b Error status 44 101 b Serial number 45 102 <ETX> End of text 46 103 <BCC1> Upper nibble 47 104 <BCC2> Lower nibble

From 21 or more monitoring instruments there are two length bytes:


1 1 <STX> Start of text 2 2 bb Length bytes (Upper byte, lower

byte) 3 4 AD Telegram identification 4 6 b Number of monitoring


instrument 1 6 8 ±nnnn±ee Measured value

7 16 b Operating status 8 17 b Error status 9 18 b Serial number

…


17.6 Control command ST

Telegram identification: ST

Telegram length: 9


Brief description: Output control words to a monitoring instrument of the monitoring station. Only one monitoring instrument is addressed.


1 1 <STX> Start of text 2 2 b Length byte 3 3 ST Telegram

identification 4 5 b Monitoring instrument

ID 5 6 b Control byte 6 7 <ETX> End of text 7 8 <BCC1> Upper nibble 8 9 <BCC2> Lower nibble

Field number 4: Main instrument (component) controls the whole monitoring station.

17.7 Control response TS

Telegram identification: TS

Telegram length: 9


Brief description: Acknowledgement of the control command as response to ST.


1 1 <STX> Start of text 2 2 b Length byte 3 3 TS Telegram

identification 4 5 b Monitoring instrument

identification 5 6 b Control byte 6 7 <ETX> End of text 7 8 <BCC1> Upper nibble 8 9 <BCC2> Lower nibble


17.8 Appendix

Protocol bytes of the AMA Instruments GC5000BTX The following charts show the configuration of the data bytes which can be sent from the AMA GC 5000 BTX Analyzer via the “Gesytec-II” protocol.

Control byte Bit 0 Start sampling Bit 1 Zero gas on (calibration gas 1) Bit 2 Span gas on (calibration gas 2) Bit 3 Not used Bit 4 Not used Bit 5 Not used Bit 6 Not used Bit 7 Not used

(Start of zero gas run needs bit 0 and bit 1 set, start of span gas run bit 0 and bit 2.)

Status byte Bit 0 System off Bit 1 Maintenance / Stand alone mode Bit 2 Zero gas running (calibration gas

1) Bit 3 Span gas running (calibration gas

2) Bit 4 Program step sampling running Bit 5 New results Bit 6 Not used Bit 7 Not ready

Error byte Bit 0 Pre-cooling alarm enrichment tube Bit 1 Sample alarm Bit 2 Carrier gas alarm Bit 3 Ignition of FID not possible Bit 4 FID too cold Bit 5 FID too cold for 8 minutes Bit 6 Not used Bit 7 Communication breakdown to

MFC / Temp. controller

Status and error byte show the current state of the analyzer. Note: While transmitting results, these status and error bytes indicate the analyzer status during data acquisition only.


18 Digital I/O

18.1 General

If you have a board with digital inputs and outputs in your analyzer, you can

remote-control the analyzer via the digital inputs and read the analyzer’s

status and alarms via the digital outputs. The following scheme shows how

to connect the inputs and outputs correctly:


18.2 Digital outputs

1. Sample 1 – 6

These three outputs are binary coded for the representation of 6 Sample

inlets (with a sample stream selector).

Output Sam. 1 Sam. 2 Sam. 3 Sam. 4 Sam. 5 Sam. 6 Cal.gas 1 Cal.gas 2

1 H L H L H L H L

2 H H L L H H L L

3 H H H H L L L L

2. Gas request

These three outputs are for the controlling of gas switching devices,

permeation or dilution modules.

Output 4 = L: Zero gas request

Output 5 = L: Span gas request

Output 6 = L: Sample gas request

3. GC not ready

This output is low while the GC is not ready

4. System alarm

This output is low while the system has an error (The status in the main

window is red).

5. Service mode

This output is low while the service mode is set.

6. Calibration running

his output is low while a calibration is running

7. Validation running

This output is low while a validation is running

8. Validation warning

This output is low when you got a warning during a validation (A warning

level is exceeded)

9. Alarm 1 – 4

These four outputs are for high alarms or low alarms for monitored

components. You can configure the alarms in the alarm configuration

window (see chapter 11.3.11)


18.3 Digital inputs

You have to set an input to low signal for at least two seconds to send a

control command securely.

1. Stop

You can stop a running cycle with this input.

2. Start with sample 1 – 6

You can start an analysis from the corresponding sample inlet with

these six inputs. If you do not have a sample stream selector, you have

to use the input for a start with sample 1.

3. Start with zero gas (cal.)

You can start a calibration run with zero gas (calibration level 1) with this

Input.

4. Start with span gas (cal.)

You can start a calibration run with span gas (calibration level 2) with

this input.

5. Start with zero gas (val.)

You can start a run with zero gas (calibration level 1) with this input but

no new calibration data is produced.

6. Start with span gas (val.)

You can start a calibration run with span gas (calibration level 2) with

this input but no new calibration data is produced.

7. Start auto calibration

You can start an auto calibration with this input. The system makes one

run with zero gas and one run with span gas.

8. Start initial validation

You can start an initial validation with this input.

9. Start standard validation

You can start a standard validation with this input.

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