AMA Instruments GC 5000 Series User manual

OPERATING MANUAL
Gas Chromatograph – GC 5000 Series

Address of manufacturer:
AMA Instruments GmbH
Soeinger Straße 100
89077 Ulm, Germany
Tel [phone]
Fax [phone]
Imprint:
Operating Manual GC 5000 Series
Version 6.0; English
Date: 09/2014

Operating Manual GC 5000; Version 6 English – Date 05/2014 1
Table of Contents
Page
1.0 Information for the owner …………………………………………………........... 4
1.1 How to use the manual ……………………………………………………………… 4
1.2 Specific normal operation …………………………………………………………… 4
1.3 Delivery information …………………………………………………………………. 5
1.4 Standard and regulations …………………………………………………………… 6
1.5 Declaration of conformity …………………………………………………………… 6
1.6 Copyright ……………………………………………………………………………… 7
1.7 Service address ……………………………………………………………………… 7
2.0 Hazard Information ………………………………………………………………… 8
2.1 General hazard information ………………………………………………………… 8
2.2 Responsibility of the operator ………………………………………………………. 9
3.0 Product description - technical specifications ……………………………….. 10
3.1 Normal use of GC 5000 BTX ……………………………………………………….. 10
3.2 Normal use of GC 5000 VOC ………………………………………………………. 11
3.3 Normal use of GC 5000 Process….……………………………………………….. 12
3.4 Hardware description ……………………………………………………………….. 11
3.5 Description of GC components .…………………………….……………………… 14
3.5.1 System control and watchdog…..………………………………………………….. 14
3.5.2 GC oven ………………..…………………………………………………………….. 14
3.5.3 Columns………………………………………………………………………... ……. 14
3.5.4 Detector……………………………………………………………………………….. 14
3.5.5 Setup of parameters….……………………………………………………………… 14
3.6 Technical data - GC 5000 ……..…………………………………………………... 15
3.7 Options…………………………………………………………………………………. 17
3.7.1 Calibration gas selector (optional)………………………………………………….. 17
3.7.2 Ozone precursor monitoring system (optional) ...………………..……..………… 17
3.7.3 Optional modules (Accessories for GC 5000) ……………………………………. 18
3.7.3.1 Dilution Calibrator DIM 200 ….……………………………. ….…………..………. 18
3.7.3.2 Zero air generator ZAG 300……..…………………………. ….…………..………. 20
3.7.3.3 Hydrogen generators – HG 300 and HG 500.……………. ….…………..………. 21
4.0 Installation …………………………………………………………………………… 23
4.1 Safety instructions…………………………………………………………………… 23
4.2 Installation condition ………………………………………………………………… 24
4.3 Gas connections …………………………………………………………………….. 24
4.4 Electrical connections ………………………………………………………………. 25
5.0 Start up and shut down ..……..…………………………………………………… 26
5.1 Safety instructions …………………………………………………………………… 26
5.2 Start up instructions …………………………………………………………………. 27
5.3 Decommissioning…….. …………………………………………………………….. 29
6.0 Setting up the GC 5000 Software ……………..…………………………………. 30
6.1 Control tab…. ……………………………………..………………………..………… 30
6.2 Status tab ……………………………...………….………………………………….. 31
6.3 Events tab ………………………………………….…………………………………. 32
6.4 How to unlock – password protection ...…………………………………………… 33
6.5 Control modes ……………………………………………………………………….. 34
6.6 Communication parameters (optional) ..………………………………..…………. 34

Operating Manual GC 5000; Version 6 English – Date 05/2014 2
Page
7.0 Starting operation …..…………………………………………………………..… 37
7.1 How to start measurement…………………………………………………………. 37
7.2 How to adjust the retention time windows………………………………………… 41
7.3 How to stop measurements ………………..……………………………………… 43
8.0 Calibrating and validating ..……………………………………………………… 44
8.1 Calibration ..…………………..……………………………………………………... 44
8.1.1 Calibration intervals .……..………………………………………………….……… 44
8.1.2 Calibration setup ……………………………………………..……………….…….. 44
8.1.3 How to start a calibration…………………………….……………………………... 46
8.1.4 Check the results of the calibration ………………………………………………. 50
8.2 Validation………………………..……………………………………………………. 54
8.2.1 Principle of validation ..…..…………………………………………………………. 54
8.2.2 Types of validation ..…………………………….………………………………….. 54
8.2.3 Validation setup …………………………………….………………………………. 55
8.2.4 How to start validation .…………………………….………………………………. 57
8.2.5 Check the validation status .……………………….………………………………. 58
9.0 Time program ……………....……………………………………………………… 59
9.1 How to setup the time program .…………………………………………………... 59
9.2 How to start the time program .…………………………………………….……… 60
10.0 Functional description ..…………………………………………………………. 62
10.1 Measuring principle BTX……..…….………………………………………………. 62
10.2 Measuring principle VOC…..………………………………………………………. 63
10.3 Measuring principle Process………………………………………………………. 65
11.0 Maintenance ………………………………………………………………………... 66
11.1 Security instructions ………………………………………………………………… 66
11.2 Maintenance schedule ……………………………………………………………... 67
11.3 Maintenance work …………………………………………………………………... 68
11.3.1 Exchange the enrichment tube (BTX) ……………………………………………. 68
11.3.2 Maintenance of the pump ………………………………………………………….. 69
11.3.3 Exchange the input filter of the MFC ……………………………………………… 69
11.3.4 Exchange or repair the capillary column ………………………………............... 70
11.3.5 Adjust the detector signal ………………………………………………………….. 72
11.3.6 Adjust the ignition voltage ………………………………………………………….. 72
11.3.7 Check the glow plug ………………………………………………………………… 72
11.3.8 Check the thermocouples ………………………………………………………….. 73
11.3.9 Check the heating units of detector and valve oven ……………………………. 73
11.3.10 Exchange of the PID lamp ………………………………………………............... 74
11.3.11 Clean the PID lamp window ………………………………….……………………. 75
11.3.12 Exchange the rotor of the rotary valve …………………………………………… 75
11.3.13 Exchange the GC oven motor …………………………………………………….. 77
11.3.14 Exchange the back panel fan ……………………………………………..………. 77
11.3.15 Exchange the Peltier cooler fan (BTX) …………………………………………… 78
11.3.16 FID maintenance …………………………………………………………............... 78
11.3.17 Exchange the enrichment or focusing tube (VOC) ..……………………………. 79
11.3.18 Exchange the Peltier cooler fan (VOC) ...………………………………………… 80
12.0 Troubleshooting …………………………………………………………………… 81
12.1 General faults ……………………………………………………………………….. 81
12.2 Error messages ..……………………………………………………………………. 82
12.3 Warning messages………………………………………………………………….. 86

Operating Manual GC 5000; Version 6 English – Date 05/2014 3
Page
13.0 Spare parts list …………………………………………………………………….. 88
14.0 Warranty ……………………………………………………………………………. 89
15.0 GESYTEC-II protocol ……………………………………………………………... 90
15.1 Telegram definitions…………………………………………………………………. 90
15.2 Status request MZ…………………………………………………………………… 90
15.3 Status response ZM…………………………………………………………………. 91
15.4 Data request DA ..…………………………………………………………………… 92
15.5 Data response AD…………………………………………………………………… 92
15.6 Control command ST ………………………………………………………………. 94
15.7 Control response TS ………………………………………………………………... 94
15.8 Appendix ………..……………………………………………………………………. 95
16.0 Analog outputs …………………………………………………………………….. 96
16.1 Analog outputs connection …………………………………………………………. 96
16.2 Analog outputs configuration .……………………………………………………… 97
17.0 Digital I/O …….….………………………………………………………………….. 99
16.1 General ………………………………………………………………………………. 99
16.2 Digital outputs ………………..……………………………………………………… 100
16.3 Digital inputs …………..……..……………………………………………………… 102
18.0 Digital outputs for external calibrators……………………………………….. 103

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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 3.1- 3.3 as 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 
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.


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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
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.

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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.