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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 2
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 3
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
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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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 5
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)
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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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 7
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.
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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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 9
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.
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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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 11
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 12
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
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Fig. 2: Rear view
Fig. 3: Gas regulation inside the analyzer
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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.
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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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 16
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 17
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 18
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
Case 19” plug-in case
Height 3 height units
Depth 400 mm
Weight 8 kg
Mounting designed for cabinet / rack mounting
Ambient temperature 5°C to 40°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 100-240 VAC
Line frequency 50 to 60 Hz
Power consumption max. 200 W
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 19
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 20
Technical data SSM 600:
General
Case 19” plug-in case
Height 3 height units
Depth 400 mm
Weight 8 kg
Mounting designed for cabinet / rack mounting
Ambient temperature 5°C to 40°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 100-240 VAC without pump; 220-240VAC with pump (110-120 VAC
optional)
Line frequency 50 to 60 Hz
Power consumption max. 200 W
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 21
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).
Operating Manual GC 5000 BTX; Version 5 – 11/2010 22
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 23
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!
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 24
5 Start up
5.1 Safety instructions
Warning!
Please read following operating instructions carefully before starting
operation.
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. 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!
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).
Operating Manual GC 5000 BTX; Version 5 – 11/2010 25
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 26
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!
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
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 27
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!
Electrical parts apply voltage while in use. Disregard may result in death,
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.)
Operating Manual GC 5000 BTX; Version 5 – 11/2010 28
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.)
Operating Manual GC 5000 BTX; Version 5 – 11/2010 29
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 30
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 31
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 32
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 33
Fig.5: Connection of analog outputs
Operating Manual GC 5000 BTX; Version 5 – 11/2010 34
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.
Referring to the selected values displayed in the window above, we get the
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 35
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.
Parameters Remote control Gesytec specifications
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 36
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 37
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 38
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 39
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 40
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 41
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 42
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 43
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 44
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 45
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
The following window pops up:
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:
Operating Manual GC 5000 BTX; Version 5 – 11/2010 46
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:
Operating Manual GC 5000 BTX; Version 5 – 11/2010 47
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“.
The following window pops up:
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 48
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 49
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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 50
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 51
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 52
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 53
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:
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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
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.
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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
The following window pops up:
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
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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
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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
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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
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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
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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
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How to run initial validation:
1. Select
Menu bar Run validation Initial validation
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
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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:
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• 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:
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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:
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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.
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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.
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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.
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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.
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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).
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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
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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.
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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.
The following window pops up:
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.
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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.
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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.
Parameters Remote control Gesytec specifications
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.
• With the Quit button you can leave this window without any change.
COM Parameter
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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.
• With the Quit button you can leave this window without any change.
Remote control Gesytec specifications Number of components:
The following window pops up:
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
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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
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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.
The following window pops up:
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”.
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11.3.6 Analysis
Menu bar Parameter Analysis
The following window pops up:
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.
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11.3.7 GC Oven
Menu bar Parameter GC oven
The following window pops up:
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:
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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.
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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
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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.
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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
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.
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
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11.3.9 Validation setup Menu bar Parameter Validation setup
The following window pops up:
Here you can configure all parameters for auto-validations.
The validation setup is described in chapter 9.5.
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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.
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 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.
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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.
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Referring to the selected values displayed in the window above, we get the
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.
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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.
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Menu bar Parameter CP File Editor
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
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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.
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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.
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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.
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Menu bar Parameter CP File Editor
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
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• 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.
.
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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
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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.
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Calibration file (CAL) Misc options tab Perform an update:
The following window pops up:
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
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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
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Purging of sample line
Sampling
Waiting for GC Ready
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Injection
Waiting for end of cycle time
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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
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Purging of sample line
Sampling
Waiting for GC Ready
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Injection
Waiting for end of cycle time
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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
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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
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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
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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.
The following window pops up:
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
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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
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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
Menu bar Run validation Initial validation
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
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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:
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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
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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.
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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
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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.
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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.
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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.
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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.
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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:
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13 Maintenance
13.1 Security instructions
Warning!
Electrical parts apply voltage while in use. Disregard may result in death,
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
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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
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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
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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.
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13.3.4 Exchange or repair the capillary column
Warning!
Electrical parts apply voltage while in use. Disregard may result in death,
physical injury or damage to property. Disconnect the GC 5000 from the
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.
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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.
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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.
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13.3.7 Check the thermocouples
Warning!
Electric parts apply voltage while in use. Disregard may result in death,
physical injury or damage to property. Disconnect the GC 5000 from the
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!
Electrical parts apply voltage while in use. Disregard may result in death,
physical injury or damage to property. Disconnect the GC 5000 from the
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.
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13.3.9 Exchange of the PID lamp
Warning!
Electrical parts apply voltage while in use. Disregard may result in death,
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.
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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
Operating Manual GC 5000 BTX; Version 5 – 11/2010 129
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.
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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.
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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.
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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.
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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.
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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.
4. The sample way is
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.
5. The sample way is
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 135
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
6. The sample way is
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.
7. The sample way is
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 136
Type of Alarm Cause Detect and Repair
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.
Result: The signal in the main menu has to be
> 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.
Result: The signal in the main menu has to be
> 100 mV when the FID flame is lit. In case the
flame does not lit, the signal has to be
< 100 mV.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 137
Type of Alarm Cause Detect and Repair
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.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 138
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).
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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!”
Built-in computer gets no
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:
“Malfunction of the
GC oven 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 9:
“Malfunction of the
valve oven
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 10:
“Malfunction of the
enrichment stage
temperature sensor.
The program has
been stopped!”
The temperature sensor is
broken.
All heaters are turned off.
Hydrogen supply is turned off.
The enrichment tube has to be exchanged.
Operating Manual GC 5000 BTX; Version 5 – 11/2010 140
Type of Error Cause Information
Error 11:
“Communication
breakdown to sample
MFC. The program has
been stopped!”
Built-in computer gets no
connection to the sample
MFC.
This means that current sample flow values are not
shown on the display anymore.
The flow set points cannot be changed.
Error 13:
“Communication
breakdown to
hydrogen MFC. The
program has been
stopped!”
Built-in computer gets no
connection to the
hydrogen MFC.
This means that current hydrogen flow values are not
shown on the display anymore.
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
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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.
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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.
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17.3 Status response ZM
Telegram identification: ZM
Telegram length: Variable
Telegram type: Response
Brief description: Status of the monitoring instruments as reply to MZ
Field no. Start byte Data format Field description
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 3 (optional) 14 15 b Operating status 15 16 b Error status 16 17 b Serial number 17 18 b Monitoring instrument ID
instrument 4 (optional) 18 19 b Operating status 19 20 b Error status 20 21 b Serial number 21 22 b Monitoring instrument ID
instrument 5 (optional) 22 23 b Operating status 23 24 b Error status 24 25 b Serial number 25 26 b Monitoring instrument ID
instrument 6 (optional) 26 27 b Operating status 27 28 b Error status 28 29 b Serial number 29 30 b Monitoring instrument ID
instrument 7 (optional) 30 31 b Operating status 31 32 b Error status 32 33 b Serial number 33 34 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
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17.4 Data request DA
Telegram identification: DA
Telegram length: Variable
Telegram type: Command
Brief description: Data request of the monitoring station
Field no. Start byte Data format Field description
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
Field no. Start byte Data format Field description
1 1 <STX> Start of text 2 2 b Length byte 3 3 AD Telegram identification 4 5 b Number of monitoring
instruments to transmit data 5 6 b Monitoring instrument ID
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
12 27 b Operating status 13 28 b Error status 14 29 b Serial number 15 30 b Monitoring instrument ID
instrument 3 (optional) 16 31 ±nnnn±ee Measured value
17 39 b Operating status 18 40 b Error status
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Field no. Start byte Data format Field description
19 41 b Serial number 20 42 b Monitoring instrument ID
instrument 4 (optional) 21 43 ±nnnn±ee Measured value
22 51 b Operating status 23 52 b Error status 24 53 b Serial number 25 54 b Monitoring instrument ID
instrument 5 (optional) 26 55 ±nnnn±ee Measured value
27 63 b Operating status 28 64 b Error status 29 65 b Serial number 30 66 b Monitoring instrument ID
instrument 6 (optional) 31 67 ±nnnn±ee Measured value
32 75 b Operating status 33 76 b Error status 34 77 b Serial number 35 78 b Monitoring instrument ID
instrument 7 (optional) 36 79 ±nnnn±ee Measured value
37 87 b Operating status 38 88 b Error status 39 89 b Serial number 40 90 b Monitoring instrument ID
instrument 8 (optional) 41 91 ±nnnn±ee Measured value
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:
Field no. Start byte Data format Field description
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
instruments to transmit data 5 7 b Monitoring instrument ID
instrument 1 6 8 ±nnnn±ee Measured value
7 16 b Operating status 8 17 b Error status 9 18 b Serial number
…
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17.6 Control command ST
Telegram identification: ST
Telegram length: 9
Telegram type: Command
Brief description: Output control words to a monitoring instrument of the monitoring station. Only one monitoring instrument is addressed.
Field no. Start byte Data format Field description
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
Telegram type: Command
Brief description: Acknowledgement of the control command as response to ST.
Field no. Start byte Data format Field description
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
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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.
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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:
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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)
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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.