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AMI Analyzer Manual 

Maintenance and troubleshooting  

  28 

 Maintenance and troubleshooting 

Maintenance: 

The model 210BR is virtually maintenance free other than for periodic calibration and occasional sensor 
replacement.   

Periodic Calibration: 

The analyzer should be calibrated about once every month to obtain the best accuracy.  The sensor typically 
declines in sensitivity by about 1% per month, so a monthly calibration is usually satisfactory.  Use in a 
particularly aggressive environment may degrade the sensor faster: in this case calibrate more often. 

You can see the calibration history using the user interface as described in the previous section of this 
manual. 

Sensor Replacement: 

This should be done based on the Span Factor feature, rather than as a response to a dead sensor.  See the 
chart below for recommended sensor replacement. 

Sensor 

Part 
number 

Description 

Warrantied life 

P-2

4SEN03 

Percent oxygen 0-25% - inert gas 

9 months 

P-3

4SEN04 

Percent oxygen – 0-25% CO2 background 

6 months 

P-4

4SEN08 

Percent oxygen – 0-100% - inert gas 

6 months 

P-5

4SEN19 

Percent oxygen – 0-25% CO2 with 500ppm 
H2S 

6 months 

Table 1.  AMI percent sensor types

Summary of Contents for 210BR

Page 1: ...08 31 2018 Made in the USA AMI Oxygen Analyzer Manual Model 210BR Costa Mesa CA ...

Page 2: ...AMI Analyzer Manual Contents i ...

Page 3: ...rranty 4 Receiving the analyzer 4 Important 5 Points to consider first 5 Location 6 Safety Considerations 7 Installation Procedure 8 Analyzer Description 20 Basic description 20 Drawings 21 General Information 23 Basic knowledge about oxygen measurement 23 Analyzer operation 24 Sample tubing and components 24 Exhaust 24 Calibrating the analyzer 24 Using the analyzer 26 Output Range 26 ...

Page 4: ...tenance and troubleshooting 28 Maintenance 28 Periodic Calibration 28 Sensor Replacement 28 Sensor replacement cautions 29 Sensor replacement procedure 29 Troubleshooting 30 Basics of oxygen troubleshooting 30 Accessories 34 Specifications and Disclaimer 37 Specifications 37 Disclaimer 38 ...

Page 5: ...a wide variety of flammable gas applications in general purpose and Class 1 Division 1 Group BCD hazardous areas such as natural gas petrochemical refining and head space monitoring With the optional demister and liquid rejection probe accessory it provides a complete system for monitoring trace oxygen in harsh environments with difficult hot and wet samples Please verify that the analyzer was not...

Page 6: ...ually unaffected by hydrocarbons or other oxidizable gases Integrated sample system Metering valve flow control H2S resistant sensor up to 10ppm H2S Optional 500ppm H2S resistant sensor available High accuracy and fast response Large liquid crystal display Bi directional serial output with simple protocol Bi directional Modbus support over RS485 multi drop loop Backed by a two year warranty exclud...

Page 7: ...ranted to operate for a period determined by its class If the sensor ceases to operate correctly before this time has elapsed contact AMI for a return authorization for evaluation If there is any evidence of defective material or workmanship the sensor will be replaced free of charge NOTE Any evidence of abuse or physical damage such as a torn membrane will void the warranty Instrument Warranty An...

Page 8: ...t is available with a built in pressure regulator for high pressure lines up to 1200psig Power supply if you are going to run the unit off solar power using a battery you need to size both the battery and the solar panel correctly The analyzer draws about 30mA at 14 4 volts but if you select the 4 20mA output option this will go up to about 60mA A heater draws up to 1 67A when the temperature is a...

Page 9: ...neral purpose Class 1 Division 1 Group B C D area or Class 1 division 2 Group B C D area When equipped with the optional heater or the extreme weather enclosure it may be mounted outdoors though it should be given a sun shield if in direct sunlight consider using the solar panel if one is used as the sunshield Mount it at a suitable viewing level ...

Page 10: ...gned for installation in either a general purpose or a Class 1 Div 1 or Div 2 Group B C D area but it is also designed so that a hazardous gas may be introduced into its main enclosure the box on the right hand side as it is intrinsically safe This gas may be any group B C or D gas The unit consists of two enclosures mounted on a back panel The smaller enclosure on the left is explosion proof and ...

Page 11: ...at a convenient eye level not too close to the right wall The basic analyzer is designed for operation between 25ºF and 115ºF It is available with a heater which expands its temperature range to 20ºF and an additional extreme weather enclosure which expands it to 40ºF The gas connections are made on the right side of the analyzer while the electrical connections are at the bottom of the explosion ...

Page 12: ...he pressure is too low the gas flow will be low and the response time long and if the flow is very low the effect of minor leaks will become significant If the pressure is too high the analyzer will be damaged and you may get a hazardous situation if the sample is flammable The response time will depend on the length of tubing the diameter and the flow rate of gas through it You can roughly calcul...

Page 13: ...in this procedure you shouldn t have the sensor in place yet Don t use the metering valve to shut off the flow as it is a fine adjustment valve 7 Pressurize the sample line to line pressure 1 150psig The exact pressure doesn t matter we want enough so that you can easily see leaks in the following step 8 Leak check every fitting and weld from the analyzer inlet to the sample tap Use a liquid soap ...

Page 14: ...n proof enclosure you have just made an igniter for the first time you get a gas leak Explosion proof seal offs are devices that allow you to put potting compound around the wires going into and out of the enclosure so that burning gases can t get past them This compound also means that you can t remove the wires in the future and if you don t use the universal couplers we recommend and can supply...

Page 15: ...robably have to perform an output calibration described later in this manual The two terminals marked A and B are for the RS 485 ModBus connection This is not isolated from ground There are two alarm contacts These are two independent switches that either close or open their two terminals Think of them as being like a single pole light switch You can determine whether they close upon an alarm or o...

Page 16: ...AMI Analyzer Manual Installation Procedure 13 ...

Page 17: ... by up to 50mA if the unit is powered from DC Note that if you change the position you will have to recalibrate the output using the AMI software The output 4 20mA circuit is capable of driving a 600 Ohm load while the voltage output needs at least a 10 000 Ohm load Either will saturate at more than 125 of the nominal full scale range Using AMI software you can set the output to 4mA 12mA and 20mA ...

Page 18: ...ing the OUTPUT RANGE button and then scroll the number on the screen with the UP and DOWN arrows until it says what you want When you have set the output range set the alarms The alarm set point is shown as a ppm or percentage value but it is internally stored as a percentage of the output range you just chose If you change the range the alarm set points will change along with it Note that this ra...

Page 19: ...nects b Set the analyzer clock time and click on Clear Data Log The analyzer stores its readings for about two weeks for you to look at subsequently It may have some readings stored from the check out process and these might confuse you when you subsequently view them Also we set it up on PST and your time zone may be different So set the time and clear the data In due course click on the Download...

Page 20: ...uring the next step 18 Unscrew the cell cap and install the oxygen sensor Unscrew the cap first Open the sensor bag remove the sensor by holding the little handle and put it into the cell compartment gold side up and with the little metal tag on the side facing you When it is in place hold the sensor in place and pull out the tag Do it in this order so that the sensor is always operating eating up...

Page 21: ...d fittings so that you don t destroy the span inlet fitting on the analyzer This can be purchased from AMI as an option Compression fittings can only take a few openings and closings before they cease to seal well enough for a trace oxygen analyzer Flow the gas through the tubing while you attach it to the span fitting screw it on by one thread allowing the gas to escape around it and after about ...

Page 22: ...w calibration j Let it go back to normal operation the SPAN flag goes out on the LCD display then press the UP arrow and note the number displayed the Calibration factor You can use this to get an idea of the remaining cell life in the future The analyzer also stores the calibration values in memory so you can view the history later When the sensor is new it will have a Calibration factor also cal...

Page 23: ...ng the oxygen sensor and also the controls and analytical circuitry Optionally it may also contain a heater for low temperature operation The circuitry in this right hand enclosure is intrinsically safe meaning that it cannot cause ignition of any flammable gas mixture The enclosure on the left is explosion proof It contains the power supplies the alarm contacts and output circuitry the user conne...

Page 24: ...AMI Analyzer Manual Analyzer Description 21 Drawings Figure 7 Outline Drawing Figure 8 Flow schematic ...

Page 25: ...AMI Analyzer Manual Analyzer Description 22 Figure 9 Control drawing AC unit Figure 10 Control drawing DC unit ...

Page 26: ...ried about oxygen mostly because nitrogen does not matter normally to the chemistry we are worried about we can think of air as being pure oxygen at 3 psia pressure In a pure gas stream or in natural gas there is zero oxygen ideally i e it is at zero pressure This means that if there is a leak in the piping there exists a pressure difference of 3psia forcing oxygen into the leak The oxygen doesn t...

Page 27: ...ble tubing with O ring seals on its fittings so that you don t damage the analyzer fittings by making and breaking them too often Exhaust The exhaust port of the analyzer should be given at least a foot of tubing but it should not be allowed to become pressurized or the readings will be affected It should be vented outdoors or brought into a scavenging system If the latter have the scavenging syst...

Page 28: ...n port open If you use compressed air go through the same procedure as above only adjust the oxygen reading to 20 9 If you do not have compressed air turn the flow selector valve to OFF and unscrew the cell cap on the front of the analyzer Blow some air under the sensor by waving a hat or some such at it Adjust the reading as before to 20 9 and then turn the flow selector valve back to SAMPLE Then...

Page 29: ...and the alarms will de activate since they now correspond to 10 0 and 12 5 i e still 40 and 50 of range However if the alarms were set to latch you would have to acknowledge them by pressing the ALARM BYPASS button before they would de activate Output ranges 0 1 0 5 0 10 0 25 Security Through the user interface three levels of security can be set These are No security all front panel controls are ...

Page 30: ... advanced features that are only accessible through the AMI User Interface For details see the User Interface manual The features include a data log a calibration log power failure log and many other detailed bits of data Most of these features are also available over the ModBus link ...

Page 31: ...ressive environment may degrade the sensor faster in this case calibrate more often You can see the calibration history using the user interface as described in the previous section of this manual Sensor Replacement This should be done based on the Span Factor feature rather than as a response to a dead sensor See the chart below for recommended sensor replacement Sensor Part number Description Wa...

Page 32: ...e MSDS to learn about potential hazards and corrective actions in case of any accident Figure 11 Inserting sensor in cell block Sensor replacement procedure 1 Turn off the sample gas flow using the flow selection valve on the front panel 2 Unscrew the cell cap 3 Remove the old sensor 4 Open the bag containing the new sensor 5 Push the new sensor into the block using its handle as shown above 6 Hol...

Page 33: ...by changing the sample flow rate If the oxygen reading decreases as you increase the flow rate that is a sure sign of a leak since the intake of oxygen is pretty constant but the dilution of that oxygen by the sample is of course greater with a higher flow rate If you time how long it takes for the reading to decrease the distance to the leak source is more or less proportional to the time it take...

Page 34: ...ower plug is seated in its socket all the way and that no whiskers of wires are shorting to each other or to the cover 4 If the user interface can talk to the analyzer but nothing shows on the LCD the analytical board or the connection to it has failed 5 If the LCD shows a number and once a minute shows Err the power board has failed or the internal communication has failed Analyzer reads too low ...

Page 35: ...n replace the cap on the cell block again Pressurize the system to line pressure less than 150 psig and leak check all the fittings and tubing including the sensor block penetrations such as the sensor wire seals nylon plugs and epoxy seals on the top of the cell block NOTE Be careful not to get soap solution on the PC boards Analyzer reads zero 1 Verify that the sensor is in the correct position ...

Page 36: ...o output alarm indication 1 Verify the alarm set points are correct press the appropriate switch on the front panel and check the displayed reading on the LCD for correct setting 2 Make sure you understand that the relays act purely as switches they either connect the two terminals or they disconnect them 3 Make absolutely sure you haven t connected the power hot to one terminal and the ground to ...

Page 37: ...ned for Class 1 Div 2 Group C D Area Classifications Long life pump and motor 20 000 hrs continuous Unique pump diaphragm that is virtually non diffusive for low level trace applications Power requirements 12VDC 700mA Extreme weather enclosure NEMA 4X Enclosure allows for our heated Model 210BR 210BR and 3010BR to be quickly and easily mounted in place for use in extreme cold wet and windy weather...

Page 38: ... return via gravity back to the gas pipeline The Demister prevents liquids from accumulating down stream in expensive analytical instruments causing costly repairs and down time Calibration tubing This unique high pressure non diffusive sample gas tubing is outfitted with special connection fittings Designed with an o ring swage seal and requiring only finger tightening the tubing and fittings are...

Page 39: ... Available for all 1 4 swage type compression fittings 6 500psig Rating Calibration gas regulator This gas nipple with o ring seal eliminates common leaks associated with imperfect metal to metal surfaces that are common when mating high pressure gas cylinders to pressure reducing regulators This inexpensive brass nipple and o ring combination provides a simple and reliable solution to the common ...

Page 40: ...rift 1 of full scale in 4 weeks at constant temperature dependent on sensor Expected cell life 6 months to 2 years dependent on sensor Response times upscale 90 of full scale in less than 30 sec dependent on sensor Outputs 1 5V or 4 20mA isolated Alarm contacts 117VAC 5A or 28VDC 5A resistive Power requirements 12 24VDC 80mA or 117VAC 1W power increases to 25W with optional heater Absolute Maximum...

Page 41: ...s or associated components AMI s obligation is expressly limited to the analyzer itself The AMI analyzer is not designed as a primary safety device that is to say it is not to be used as the primary means of assuring personnel safety In particular it is not designed to act as a medical instrument monitoring breathing air for correct oxygen concentration and should not be used as such when it is th...

Page 42: ...thout either indicator for Canada only Issued by Oong Lee PRODUCTS CLASS 4828 02 SIGNAL APPLIANCES Toxic Gas Detection Instruments For Hazardous Locations CLASS 4828 82 SIGNAL APPLIANCES Toxic Gas Detection Instruments For Hazardous Locations Certified to U S Standards Class I Division 1 Groups B C and D Series 2010BR and 210BR Oxygen Analyzers and series 3010BR Hydrogen Sulfide Analyzers input ra...

Page 43: ...on It is the responsibility of the manufacturer to provide and apply these additional markings where applicable in accordance with the requirements of those authorities The products listed are eligible to bear the CSA Mark shown with adjacent indicators C and US for Canada and US indicating that products have been manufactured to the requirements of both Canadian and U S Standards or with adjacent...

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