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AMI Analyzer Manual

Maintenance and troubleshooting

••••

3. Verify that the output connections are not shorted all the way back to the recording device. Disconnect

the wires from the analyzer and use an ohmmeter to check for shorts or opens.

4. Verify that the unit is set to the correct output. Remove the output board cover and verify that the

jumpers are in the correct positions (on the left for current output, on the right for voltage output). If

not, place them correctly.

No 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. Verify that the connections on the terminal block are properly stripped and correct.

3. Verify that the alarms are configured correctly, using a PC or similar communication device.

4. Verify the alarm delay time with the PC.

5. Verify that the output connections are not shorted all the way back to the recording device. Disconnect

the wires from the analyzer and use an ohmmeter to check for shorts or opens.

Incorrect readings

1. Verify that there are no leaks in the system.

2. Verify that the span gas bottle is correctly marked by comparing its reading when the analyzer has been

spanned on air to what it actually says.

3. If spanning on air, verify that the air source is free of water vapor (humid air will contain about 3% less

oxygen than expected, depending on temperature), and that bottle air does actually contain 20.9%

oxygen. Manufactured air often does not!

Analyzer refuses to accept front panel settings

1. Using the RS-232 interface, verify that the security is set the way you want it.

Still no correct operation

Call AMI at 714 848 5533, and ask for Technical
assistance.

Or contact us by email at sales@

AMIO

2.com.

Содержание 201RSP

Страница 1: ...AMI Analyzer Manual Contents i AMI Oxygen Analyzer Manual Model 201RSP AMI Costa Mesa CA ...

Страница 2: ...sensor 3 Sensor Warranty 3 Instrument Warranty 3 Receiving the analyzer 3 Important 4 Points to consider first 4 Installation and Operation 6 Receiving the analyzer 6 Installation 6 Location 6 Short form Installation Procedure 8 Laptop set up procedure 10 Expanded Installation Procedure 11 Interconnections 21 Alarm connections 21 Output connections 21 ...

Страница 3: ...et Points 26 Alarm Hold Off 26 Calibration Spanning 26 Verify Span Factor 27 Read the Temperature 27 Alarm Functionality 28 Communications 30 Basics 30 USB communication 30 Communication program 31 Top section 32 Analyzer Info Section 32 Analyzer Setup Section 33 Sensor Calibration Data 35 Data Logging 36 Variables 38 RS 485 Modbus Introduction 39 RS 485 Modbus Communication 40 Overview 40 Command...

Страница 4: ...oubleshooting 48 Maintenance 48 Periodic Calibration 48 Sensor Replacement 48 Sensor replacement cautions 49 Troubleshooting 50 All oxygen applications 50 Specifications and Disclaimer 53 Specifications 53 Disclaimer 54 Index Error Bookmark not defined ...

Страница 5: ...ee performance Several aspects of the design are the subject of patents number 5 728 289 and 6 675 629 the sensors are also covered by a patent number 7 316 768 Please verify that the analyzer was not damaged in transit If so please contact the shipper as well as AMI Caution Read and understand this manual fully before attempting to use the instrument In particular understand the hazards associate...

Страница 6: ...n gas calibration no zero gases required Virtually unaffected by hydrocarbons or other oxidizable gases High accuracy and fast response H2S resistant sensor up to 10ppm H2S Optional 500ppm H2S resistant sensor available Large liquid crystal display Bi directional serial output with simple protocol Backed by a two year warranty excluding sensor Standard isolated 4 20mA output Two fully adjustable a...

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

Страница 8: ... supply The unit contains a switching power supply that is insensitive to AC voltage or frequency changes over a wide range It will work with any normal UPS system if desired Electrical connections Following best electrical practices run the analog output connections separately from the power and alarm connections Modbus communications if used should be run with the analog output wiring using twis...

Страница 9: ...ortant 5 In addition since the analyzer includes a pump you have to take care that you do not pressurize the sensor with the span gas It will be necessary to use a bypass valve and flow meter on the span inlet of the analyzer ...

Страница 10: ...e mounted in a panel in a general purpose area It should be mounted at a suitable viewing level Refer to the drawing figure 1 showing the analyzer dimensions It is not suitable for use in a hazardous area Although the unit is RFI protected do not to mount it close to sources of electrical interference such as large transformers motor start contactors relays etc Also avoid subjecting it to excessiv...

Страница 11: ...AMI Analyzer Manual Installation and Operation 7 Figure 1 Outline and Cut Out Drawing 8 60 3 00 5 05 9 00 7 92 4 81 Ø0 21 X 4 Analyzer case outline dashed Cut out Front panel outline ...

Страница 12: ... approximately 1 SCFH with the Flow control valve 12 Allow the sample gas to purge the unit for a few minutes Make sure the cell cap is in place 13 If you are not using the advanced features set up the alarms and the output range from the front panel of the analyzer 14 Optional a Connect the laptop run the User Interface version III and verify all alarm output and security settings b Set the analy...

Страница 13: ...valve and leak check all the tank fittings gauges and packing glands with Snoop or equivalent liquid leak detector not spray c Connect a bypass flow meter and a series valve at the inlet of the span fitting The analyzer s pump will suck a sample out of this line and you want the inlet pressure to be atmospheric You can control the bypass flow with the valve while the analyzer is drawing its sample...

Страница 14: ...e boxes with numbers or words 8 If you want to name the analyzer click on the User ID box A dialog box will come up asking for a password Use AMI in capitals as the password and then write in up to 12 characters as a name for the analyzer 9 Set up the output range that is the range used by the analog output and the alarms to scale the output for your monitoring device 10 Make sure the security set...

Страница 15: ... issues 1 Mount analyzer at a convenient eye level The basic analyzer is designed for operation between 25ºF and 115ºF It is available with a heater but this is intended only to stabilize its temperature if it to be measuring in pure CO2 The gas connections are made on the left side of the back of the analyzer while the electrical connections are at the bottom of the back The analyzer is intended ...

Страница 16: ...ring valve to shut off the flow as it is a fine adjustment valve 4 Pressurize the sample line to line pressure 1 10psig The exact pressure doesn t matter we want enough so that you can easily see leaks in the following step 5 Leak check every fitting and weld from the analyzer inlet to the sample tap Use a liquid soap solution such as Snoop or similar Don t spray it on You are looking for little b...

Страница 17: ...nd to increase the pressure on the sensor which will increase the oxygen reading Figure 3 The 201RSP back panel 8 Connect power relay contacts analog output and RS485 if desired If using conduit run the power and alarms in one conduit and the analog output and RS485 in the other The AC power uses a standard IEC connector like any desktop computer Although the power entry module allows you to selec...

Страница 18: ...t you won t see any flow through the flow meter as all the flow will exhaust from the cell pocket in the front 10 If you are not using the advanced features set up the alarms and the output range from the front panel of the analyzer First choose the output range This is the oxygen range that the analog output and alarms respond to For example if you use a range of 10 full scale 20mA corresponds to...

Страница 19: ...he kind often used to connect a PC to a printer to the port in the middle of the back of the analyzer Select the comm port at the top of the screen and click Open COMM The program will figure out how to communicate to the analyzer and fill in all the boxes once it connects 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...

Страница 20: ...ws mid scale vii Uncheck any checked box if you forget the analyzer will revert to its ordinary operation in ten minutes anyway 12 Test the entire system including anything controlled by the alarms or analog output using a cell simulator As an option AMI can provide a Cell Simulator that mimics the operation of a sensor between 0 100ppm so that you can verify that your control system or flow compu...

Страница 21: ...9 Purge with sample gas for half an hour or until the oxygen reading has fallen to low ppm levels it should drop to less than 0 1 in less than a minute if it has been installed properly the temperature is above 50ºF and always assuming your sample has less than 0 1 of oxygen in it Cold temperatures cause the sensor to respond more slowly You may be required to perform a low level span this means s...

Страница 22: ...on gas WHILE you are connecting the tubing to the span gas fitting Allow the gas to purge around the fitting for about 20 seconds before you tighten it If you are not going to leave the span gas tank permanently connected it is preferable to use the AMI special flexible non diffusive tubing with its O ring sealed fittings so that you don t destroy the span inlet fitting on the analyzer This can be...

Страница 23: ...perature when you put it in the reading will be quite wrong until the sensor has had a chance to equilibrate Increase the flow rate by doubling it and see if the reading decreases after a few seconds If the reading goes down with higher flow you certainly do have a leak You can also time how long it takes which will give you an indication of where the leak is The longer it takes for the flow chang...

Страница 24: ...AMI Analyzer Manual Expanded Installation Procedure 20 The analyzer is now set up and calibrated It is normally good practice to give it a day or two and recheck the calibration ...

Страница 25: ...perator presses the ALARM ACKNOWLEDGE button on the front panel The contacts can handle AC or DC voltages and can carry up to 5A of current for a resistive load Inductive loads such as solenoid valves should be snubbed we suggest that you connect diodes or Zener diodes or Transzorbs directly across them to absorb the inductive spike Do not connect them across the relay terminals on the analyzer si...

Страница 26: ... will automatically return to its normal operation after ten minutes Serial connections The 201RSP provides two serial connections a USB port that can talk to a standard PC running the AMI User Interface software and an RS485 connection that supports the standard ModBus protocol The unit detects the presence of a USB connection and disables the RS485 connection if one is detected This allows you t...

Страница 27: ...s should be at the same pressure as the sample i e ambient pressure See the diagram above for how to accomplish this The idea is that when you span the analyzer you flow some span gas out of the bypass flow meter so that the inlet to the analyzer is at ambient pressure If you don t do this the pump will fight the span tank regulator and you may have a random pressure on the sensor which will ruin ...

Страница 28: ...ou can set the analog output to correspond to 0 10 and the alarms to be say 4 0 and 5 0 i e 40 and 50 of range activating above set point If the oxygen level actually is 2 5 the display will show 2 50 and the output signal will be at 25 of full scale If the oxygen level becomes 20 0 the display will show 20 0 but the 4 20mA output will be saturated and the alarms will both be activated If you now ...

Страница 29: ...normal operation and store the new value Output Ranges The output range is the range to which the 4 20mA analog output signal and the alarm settings correspond Output ranges 0 1 0 5 0 10 0 25 0 1000ppm and 0 100 are options View Output Range Press the OUTPUT RANGE button on the front panel for a second and let go The display will show the full scale value of the output range for about three second...

Страница 30: ...show the alarm hold off time in minutes and if the analyzer was indicating an alarm it will be turned off and held off for the period of the alarm hold off time During this time the LED will glow yellow rather than red If the alarms are programmed to latch pressing this button will also unlatch them and stop them from alarming again for the hold off period If the security setting allows it the ala...

Страница 31: ...d then press and hold the UP or DOWN button until the reading matches the span gas value or if using air 20 9 The LED will remain green during this procedure Verify Span Factor The analyzer features a Span Factor display to help you determine the state of the sensor As the sensor ages its output decreases gradually and therefore the span factor has to be turned up during calibration to compensate ...

Страница 32: ...point or alternatively below the set point In either case the oxygen level will have to go a bit further the other way back for the alarm to reset in other words it has hysteresis of about 3 of range For example if the alarm is a high alarm set to go off at 10 on the 25 output range when the oxygen level gets to 10 the alarm will trigger assuming no time delay When the oxygen level subsequently dr...

Страница 33: ... time and then it will drop out The purpose of this is to drive latching solenoid valves that require a pulse of current one way to set them and then a reverse pulse of current to reset them The alarm hold off period may be set by the front panel or the user interface and by default is one minute The alarm hold off is triggered whenever the ALARM ACKNOWLEDGE button is pressed ...

Страница 34: ...The RS485 port supports ModBus RTU at 9600 baud USB communication The USB port is located on the cover panel in the explosion proof enclosure and is provided as a type B USB connector It uses a standard cable such as are often used to connect PCs to printers Through the USB interface you can operate the analyzer from your PC and you can set up its internal parameters to your liking The USB communi...

Страница 35: ... select the appropriate baud rate and determine the kind of analyzer present The ports available will be shown Depending on your particular computer the port may be anything If there are more than one available you may have to try them all until you get the one that works Note that if the analyzer loses power you will have to restart the AMI program as the USB chip will have to restart Once the pr...

Страница 36: ...d the time and date Analyzer Info Section These boxes are populated by the program from data provided by the analyzer Earlier versions of the analyzer will not provide all the data it expects so some boxes might be blank if you use this interface with legacy units The analyzer model code will be shown at the top of this section The current oxygen reading will be shown in the Reading text box The s...

Страница 37: ...none a user can adjust any of the front panel controls span only in which case he can span the unit but not set alarms the output range or the alarm time out and full in which case he can look at the settings but not change any of them When initially configuring the analyzer or installing it it is useful to be able to calibrate the analog output against the measuring device you connect it to You c...

Страница 38: ...erts the values from the analyzer which are percent of range into absolute values Over write them with the value you want and press ENTER on the keyboard to send it down to the analyzer For example if you expect the oxygen values to vary between 0 and 10 of oxygen set the Output Range to 10 If the alarm set point should be 5 oxygen write into one of the alarm Set Point boxes 5 0 and press Enter Al...

Страница 39: ...nit is calibrated via the front panel The sensor information is read only although you can submit a sensor serial number at the bottom of this section when you insert a new sensor When you put in a new sensor you can place the sensor in the analyzer and flow gas over it while you read its serial number Click on the NEW button and make sure the box marked reset sensor is checked otherwise you will ...

Страница 40: ...yzer by clicking on the Set Analyzer Time button If you change the time and date you may want to click the Clear Data button so the software doesn t get confused by later times being earlier than earlier times The analyzer logs data at a rate set by the Datalog Interval box If this is set to zero logging will actually occur at ten second intervals Typically this interval will be set to 1 minute Th...

Страница 41: ...mat for subsequent analysis so when you press the graph button the program opens a dialog box which allows you to graph any of the stored files the latest one will of course be the most recent one Double click it and the graph will appear In the graph display you can zoom into data by clicking the Zoom In button and zoom out by clicking the Zoom out button The analyzer can be left to overwrite the...

Страница 42: ...ication program It allows you to interrogate the analyzer for a particular variable manually but normally this is not necessary When the analyzer is first connected the program will fill up all the variables in the list and will then poll a subset of them regularly If desired the REFRESH button will cause the program to update every variable Mostly this screen is used for troubleshooting ...

Страница 43: ...le parameters These include reading and writing single bits called coils in Modbus terminology reading and writing certain 16 bit registers and a set of diagnostic commands The registers are separated into two types Input registers and Holding registers Input registers contain data that comes into the device and cannot be modified such as the temperature They are read with command 4 Holding regist...

Страница 44: ...n be changed over the Modbus if coil 24 is set Alternatively it can be changed as desired using the USB program Commands Command Registers Notes 1 Read coils 0 24 Corresponds to some holding registers except 24 which is the write enable bit 3 Read holding registers 0 255 Equivalent to all the AMI protocol variables except the datalog download which is not available through Modbus 4 Read input regi...

Страница 45: ...he holding registers 0 and 1 can be used with command 3 In this case the value in the holding register 0 is again the percent of the range in holding register 1 but now holding register 1 contains the output range full scale value in a similar fashion to input register 1 This register can have the values 1 5 10 50 100 500 1000 5000 10001 10005 10010 10025 and 10100 where once again the values grea...

Страница 46: ...ommunications 42 analyzer was powered down during this time Two other registers show the number of hours that the sensor saw temperatures below 32F or above 110F Finally the user info is shown in the last several registers ...

Страница 47: ...life in million ppm hours U1 8 Sensor life above 110F U2 9 Sensor life below 32F U3 10 Sensor life powered off U4 11 Last sensor life hours U5 12 Last sensor life million ppm hours U6 13 Last sensor life above 110F U7 14 Last sensor life below 32F U8 15 User info byte 0 L2 0 16 User info byte 1 L2 1 17 User info byte 2 L2 2 18 User info byte 3 L2 3 19 User info byte 4 L2 4 20 User info byte 5 L2 5...

Страница 48: ...rm state H 14 Alarm hold off time Z 60 15 Alarm 1 delay X 0 16 Alarm 2 delay Y 0 17 Pulse time W 0 0 600 18 Log period P7 1 0 60 19 N Log data position Q 0 30000 20 Sequence time 21 N Sensor temperature T0 75 22 N Last invalid address 23 Error flags I 24 N Power temperature T1 75 25 N Not supported T3 1440 26 Seconds P0 0 59 27 Minutes P1 0 59 28 Hours P2 0 12 29 Day of week P3 0 6 30 Day of month...

Страница 49: ...h 76 then 77 through 87 and then 88 through 98 The span history is structured as dd mm yy XXX YYYppm with the number of X s and Y s varying XXX is the span factor after the span and YYY is the span gas used as read by the analyzer for example if the analyzer is spanned to 80 0ppm gas this value will be 80 0ppm If it was spanned on air to 20 90 this value would be 20 9 A total of five such sets of ...

Страница 50: ...operation Closes in alarm Opens in alarm 11 Failsafe selection Attempts to alarm if power fails Doesn t 12 Alarm 2 state In alarm Out of alarm 13 Alarm 2 high low selection Alarms above set point Alarms below set point 14 Alarm 2 operation Closes in alarm Opens in alarm 15 Alarm latch selection Alarms latch Alarms automatically reset 16 Error invalid output range 1 error No error 17 Error failed i...

Страница 51: ...ode Stops the analyzer from responding to anything 10 11 08 00 0A Clear all diagnostic counters Clear each of the diagnostic counters to zero 11 11 08 00 0B Total message count The total number of messages seen by the analyzer 12 11 08 00 0C CRC error count Number of CRC errors seen by the analyzer 13 11 08 00 0D Exception count Number of invalid Modbus commands 14 11 08 00 0E Number of slave mess...

Страница 52: ...on is usually satisfactory Use in a particularly aggressive environment may degrade the sensor faster in this case calibrate more often 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 Expected life P2 4SEN03 1 0 50 in inert gas background 12 15 mo...

Страница 53: ... with water for a period of at least 15 minutes Refer to the Material Safety Data Sheet provided Dispose of leaking or used sensors in accordance with local regulations Sensors usually contain lead which is toxic and should generally not be thrown into ordinary trash Refer to the MSDS to learn about potential hazards and corrective actions in case of any accident Figure 11 Inserting sensor in cell...

Страница 54: ...ly it may be getting poisoned by acid or sulfur bearing gases such as H2S Use the H2S resistant T 4 sensor 6 Verify that the cell block connectors are in fact making contact with the cell Clean them gently with a Q tip and bend them slightly straighter so that they make a good contact Once this is done the cell should have some resistance to being removed from the block Analyzer reads too high 1 V...

Страница 55: ...her gas may be 3000 psig nitrogen or other gas lines look like a vacuum to oxygen This always surprises people who have not experienced it Analyzer reads zero 1 Verify that the sensor is in the correct position not upside down If it is upside down verify that the membrane has not been punctured i e there is no sign of electrolyte on the surface and if not put it back the right way up If you have l...

Страница 56: ...tly using a PC or similar communication device 4 Verify the alarm delay time with the PC 5 Verify that the output connections are not shorted all the way back to the recording device Disconnect the wires from the analyzer and use an ohmmeter to check for shorts or opens Incorrect readings 1 Verify that there are no leaks in the system 2 Verify that the span gas bottle is correctly marked by compar...

Страница 57: ...ational conditions Pollution degree 2 Installation category I I Drift 1 of full scale in 4 weeks at constant temperature dependent on sensor Expected cell life 9 months to 2 years Response times 90 of full scale in less than 10 seconds P2 sensor Outputs 4 20mA isolated Alarm contacts 230 117VAC 5A or 28VDC 5A resistive Note Power requirements 90 240VAC 10W Absolute Maximum Power voltage 264VAC 60H...

Страница 58: ...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...

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