AMI 210BX User manual

Operator Manual
PERCENT OXYGEN
ANALYZER
MODEL 210B

MODEL 210BX Overview ___________________________________________________ 2
Method of Measurement _______________________________________________________ 3
Key Innovations_______________________________________________________________4
Safety, Warnings & Cautions ___________________________________________________ 5
Analyzer Installation___________________________________________________________8
Part I: Mounting the Analyzer____________________________________________ 8
Part II: Electrical Connections for the Analyzer________________________________ 9
Initiation of the Pressure Sensor______________________________________15
Part III: Gas Connections_________________________________________________16
Initiation of Sample Flow __________________________________________19
Sensor Installation / Replacement _______________________________________________20
Calibration ________________________________________________________________ 22
Analyzer Operation _________________________________________________________ 26
COMMAND CENTER Interface Software Set-up____________________________________ 29
Remove the Explosion-proof Cover_________________________________________29
Establish a Communication Link ______________________________________ 29
Analyzer Output Setup _______________________________________________ 31
Alarm Setup ________________________________________________________ 34
Controls Both Alarms Setup ______________________________________________36
Datalog Column Setup _______________________________________________ 37
Download Data _______________________________________________________38
Modbus RS485 Communication Protocol ________________________________________ 41
Troubleshooting, Maintenance & Repairs___________________________________________ 45
Specifications _______________________________________________________________49
AMI®Warranty & Support___________________________________________________50
Limited Warranty/Disclaimer _____________________________________________ 50
Limitation of Liability___________________________________________________ 50
Limitation of Remedies _________________________________________________ 50
TABLE OF CONTENTS
Special Message from Advanced Micro Instruments (AMI):
Thank you for purchasing this MODEL 210BX for your Percent Oxygen measurement needs.
This permanent mount Percent Oxygen Analyzer is the industry's most advanced and
contains patented designs and innovations. You will find that it delivers the highest levels of
performance and reliability with a full suite of standard features.
Note: Read this manual carefully prior to installation.
If you have any questions, contact AMI at 714.848.5533 or www.amio2.com.
OPERATOR MANUAL
MODEL 210B
1

ANALYZER OVERVIEW
Mounting Hole
(x 4)
LCD
Up and Down
Arrow Buttons
Exhaust Port
Span Gas Inlet Port
Sample Gas Inlet Port
3-way Selector Valve
(Sample/Span/Off)
Flow Meter
½" NPT Machined
Holes for Electrical
Connnections (x 2)
(not shown in image)
Explosion-proof
Enclosure
(left side view)
(front view)
Exhaust Port
Span Gas Inlet Port
Sample Gas Inlet Port
Cell Cap
Metering Valve
Protective Earth
Ground Lug
Mounting Plate
(right side view)
Warning/Caution
Information Plate
Case Earth
Ground Lug
(Note: No Customer Connections)
2

METHOD OF MEASUREMENT:
ELECTROCHEMICAL OXYGEN SENSORS
The MODEL 210BX utilizes P Series Oxygen Sensors that feature Proprietary Sensor
Technology. We manufacture these electrochemical sensors in our state-of-the-art factory in Costa
Mesa, CA using an innovative design, which enables them to achieve the fastest 'come-down' time in the
industry and swift response times (both upscale and downscale).
Notes:
Any sensor can be used in O2applications above its recommended operating ranges, however, it may
shorten the sensor's lifespan.
The minimum range of the sensor is dependent on the sensor as well as the AMI Analyzer it is used within.
Sensitivity is the minimum change in O2in the gas stream that will be detected by the sensor.
Notify the factory for use in CO2background gas above 50%. The AMI O2Analyzer will require
additional programming.
AMI Model Number P-2
Type PERCENT
Recommended O2
Measurement Range 0 —50%
Minimum Range 0 —1,000 ppm
Sensitivity 10 ppm
Special Conditions O2in
inert gas
0 —25%
Up to
100% CO2
PERCENT
P-3
0 —1,000 ppm
100 ppm
0 —100%
Enriched
Oxygen
PERCENT
P-4
0 —1.0%
1,000 ppm
0 —25%
<500 ppm H2S
100% CO2
PERCENT
P-5
0 —1,000 ppm
100 ppm
3

Advanced Micro Instruments has developed and patented key technologies that enable our Analyzers to
deliver the highest levels of PERFORMANCE, RELIABILITY and EASE-OF-USE. These technologies are utilized
by the MODEL 210BX and are not available on any competitive offering.
Our patented ELIMINATOR CELL BLOCK™ provides a unique sample system
approach that virtually eliminates all potential leak paths while
optimizing flow efficiencies. The sample system and flow-efficient sensor
pocket are machined directly into a solid metallic block and interconnected with
precision-drilled, intersecting gas passages – eliminating the need to use long
lengths of tubing and leak-prone compression fittings. Additionally, a special
engineered 3-way selector valve, metering valve, pressure sensor and flow
meter are all integrated into the machined block.
This approach is far superior than the designs of traditional sample systems that
use multiple off-the-shelf components, numerous compression fittings and long
lengths of tubing that join everything together. The traditional, outdated
approach requires a great deal of space and is prone to leaks.
The Block even provides the user with direct front panel access for installing
and replacing sensors, as well as air calibration feature, without the need for
disassembly or tools.
This powerful software platform comes standard with every MODEL 210BX
purchase and provides users with access to a full suite of advanced features,
including:
– Settings & logic adjustments for 2-fully independent Alarm Relay Contacts
– Security settings to prevent unauthorized adjustments to the Analyzer via the
front panel
– Changing the analog outputs from 4 –20 mA to 1–5 VDC or vice versa
– Datalogger that records measurement readings, temperature of the Cell Block,
gas pressure, brown-outs and power voltage over a period of 15 days @1-min
intervals (data can be displayed on a graph or in tabular format)
– Error Status Display that alerts users to any error(s) detected by the Analyzer
– Communication with the Analyzer via USB Virtual COMport and Modbus
bi-directional RS485 Communication
KEY INNOVATIONS
ELIMINATOR CELL BLOCK™
COMMAND CENTER INTERFACE SOFTWARE
ELECTRONICS PLATFORM
command
center
The production of AMI's electrochemical oxygen sensors uses patented
technologies and manufacturing expertise that make them superior to competitive
offerings. AMI oxygen sensors deliver an extremely fast response times, high
reliability and a longer life. They also provide resistance up to 500 ppm of H2S.
PROPRIETARY SENSOR TECHNOLOGY
4

SAFETY, WARNINGS & CAUTIONS
Violation of the National Electrical Code requirements (especially Article 500 that deals with
hazardous areas) may cause a fire or explosion with the potential for serious injury or loss of life.
Make sure no hazardous gas is present in the area before and during installation.
WARNING
Drilling any holes in the enclosure will violate the safety approval and may create risk of harm.
WARNING
A WARNING identifies conditions or procedures that can be dangerous to the user.
A CAUTION identifies conditions or procedures that can cause damage to the Product.
SYMBOL TABLE
WARNING - RISK OF DANGER OR HARM
TO THE USER or RISK OF DAMAGE TO THE
PRODUCT. Consult the operator manual.
Relay
Earth Ground
DC (Direct Current)
RISK OF SHOCK (DC)
Frame Chasis Terminal
Protective Ground
AC (Alternating Current)
Due to non-conductive surfaces, there exists a POTENTIAL ELECTROSTATIC CHARGING HAZARD.
EN RAISON DE SURFACES NON CONDUCTRICES, IL EXISTE UN RISQUE POTENTIEL DE
CHARGE ELECTROSTATIQUE
WARNING
RISK OF SHOCK (AC)
5

WARNING
The following power requirements must be met by the installer of the DC/AC power connections to the
Analyzer:
•You must include an electrical disconnect means and a current limiting device, such as a
switch and fuse. The disconnect device must be marked as a 'disconnect device' and
readily accessible to shut off power to the Analyzer. This will allow the Analyzer to be
quickly shut-off in case of an emergency. The disconnect and current limiting device must
be housed in an enclosure rated for the area classification. Conduit seals may be required
on the enclosure, depending on the area classification.
DC-powered version (non-heated)
Use a 0.25-Amp fuse disconnect.
DC-powered version with heater option
Use a 2.5-Amp fuse disconnect.
DC power supply must be an approved Class 2 or limited energy circuit for DC power as
stated.
AC-powered version (non-heated)
Use a 0.20-Amp fuse disconnect.
AC-powered version with heater option
Use a 1-Amp fuse disconnect.
The voltage rating for the AC Analyzer is 100 to 240VAC at 50/60Hz ± 10%.
AC voltages outside this may cause the Analyzer to malfunction.
You must follow the National Electrical Code (NEC) in your installation. Consult the NEC Handbook
for the correct guidelines and standards.
Class I, Div 1 areas must use rigid conduit with seal-offs.
Class I, Div. 2 areas can use flexible conduit with seal-offs.
The Analyzer has approval for Class I, Division 1, Groups C and D. To comply with these
requirements you need to assure the following:
•The Protective Earth Ground Lug on the front lower left of the Analyzer mounting bracket
must be connected to the High Quality Protective Earth Ground using a16-gauge wire.
Please refer to the image on page 2 of the front view of the Analyzer for the location of the
Protective Earth Ground Lug
WARNING
6

CAUTION
The voltage rating of the DC Analyzer is 10–24V.
•DC input has to be an approved Class 2 or limited energy circuit for DC power
•Voltages outside this range may cause the Analyzer to malfunction.
The voltage rating of the AC Analyzer is 100 to 240VAC at 50/60Hz with a tolerance of +/- 10%.
•Any AC voltages outside this range may cause the Analyzer to malfunction
Any use of this equipment in a manner not specified in this manual or approved AMI documentation
may impair the protection provided by the equipment.
Toute utilisation de cet équipement d'une manière non spécifiée dans ce manuel ou dans la documen-
tation AMI approuvée peut altérer la protection fournie par l'équipement.
A SEAL SHALL BE INSTALLED WITHIN 50 mm OF THE ENCLOSURE.
UN SCELLEMENT DOIT ETRE INSTALLE A MOINS DE 50 mm DU BOITIER.
WARNING
SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY.
LE REMPLACEMENT DE COMPOSANTS PEUT COMPROMETTRE LA SECURITE INTRINSEQUE.
WARNING
Enclosure materials contain a light metal content of over 10% Aluminum and pose a potential impact
spark ignition hazard. The end user shall carry out a risk assessment prior to installation in an EPL Ga
environment and shall only install the equipment where the risk of impact has been considered to be
negligible.
Les matériaux de boîtier contiennent une teneur en métaux légers de plus de 10% d'aluminium et con-
stituent un risque potentiel d'inflammation. L'utilisateur final doit procéder à une évaluation des risques
avant de l'installer dans un environnement EPL Ga et ne doit installer le matériel que dans les cas où le
risque d'impact a été considéré comme négligeable.
WARNING
7

STEPS
1. Determine a convenient location to place the Analyzer. The location should ideally
be eye-level.
2. Mount the Analyzer to a wall or bulkhead using the 4 mounting holes or to a 2-inch (5 cm)
pipe using¼" x 2" U-brackets with ¼ nuts.
Note: Equipment shall only be installed and operated in the upright orientation with the mounting
plate vertical.
ANALYZER INSTALLATION
Part I: Mounting the Analyzer
Key Points note: Analyzer weighs 16.0 lbs (7.26 kg)
• The Analyzer can be mounted either indoors or outdoors, where the ambient temperature
remains between 25°F (-3.9°C) and 115°F (46°C)
• For installation, where temperature drops down to -20°F (-29°C), order a MODEL 210BX
with the factory-installed heater option
• For installation, where temperature drops down to -40°F (-40°C), order a MODEL 210BX
with the factory-installed EXTREME WEATHER ENCLOSURE and heater option
• When using a solar panel to power the Analyzer, we recommend mounting the solar panel just
above the Analyzer, using the same mast, to serve as a sunshield
WARNING:
For DC models, do not use above 5,500 m (18,000 ft).
For AC models, do not use above 2,500 m (8,200 ft).
WARNING:
The Analyzer weighs 16.0 lbs (7.26 kg) and can pose a risk to the user if dropped.
8

STEPS
Part II: Electrical Connections for the Analyzer
• Verify your rated power supply matches the operating voltage of your Analyzer before
you begin
• THE MODEL 210BX is available with either AC or DC Power (you must request your
desired power at the time of your purchase)
Note: Refer to page 50 for the power requirements of your Analyzer.
Note: Both alarm relays are rated for 5A @115VAC or 24VDC.
• Your Analyzer has both 1–5 VDC and 4–20mA isolated analog signals. It has been
setup at the factory per your analog output requirements at the time of purchase.
However, this can be easily changed in the field by following the instructions shown on
page 33
• Flameproof joints are not intended to be repaired
• Electrical bushing separating the Flameproof and Analytical enclosures shall not be
subject to environmental conditions which adversely affect the properties of the cement
Key Points:
1. Remove the two red plastic protective caps from the ½" NPT conduit holes on the explosion-proof
side of the Analyzer. These plastic caps protect the threads of the unit during shipping.
• We provide 2 (two) separate ½" NPT conduit holes to accommodate all electrical connections.
The first conduit opening should be used for power and alarm relay connections. The second is for
analog output and RS485 connections
Note: AC Power and the opening and closing of alarm relays produce both electrical noise and
large inductive spikes that can have an undesirable effect on the measurement readings. This is why
we provide two conduit openings and strongly recommend separating the sensitive analog signal
wiring from the power and relay wiring.
9

2. Install the conduit unions between the explosion-proof housing of the Analyzer and the electrical seal-off.
DO NOT fill the electrical seal-offs yet.
• In order to meet electrical codes for Class 1, Div 1 and Class 1, Div 2, Groups C & D, you must use
electrical seal-offs in your installation
• We recommend that you install conduit unions between the explosion-proof housing of the Analyzer and
the seal-offs. This will prove very useful in the event that you have to remove the Analyzer for servicing,
without cutting wires
Left Conduit Union
Electrical Seal-offs
Right Conduit Union
WARNING:
If you are using DC Power and intend on using
the analog output only feature (which is the
same as using 'NO RELAYS'), you can safely
run both DC Power and Analog Output Signal
in a single conduit. However, you must install
an approved ½" NPT plug for hazardous
locations in the unused ½" NPT port.
FAILURE TO DO SO WILL VIOLATE ALL
SAFETY REQUIREMENTS AND POTENTIALLY
RESULT IN AN EXPLOSION!
10

5. Verify the operating voltage of your Analyzer and the correct power requirements before
you continue.
6. Make sure the power source has been turned-off before you begin installing wiring.
3. Remove the explosion-proof cover by rotating it counterclockwise.
Note: A white sheet metal panel inside the explosion-proof housing indicates DC, while a
black sheet metal panel indicates AC power.
4. Then remove the Terminal Cover to access the electrical connections.
Terminal Cover
DC Version with Terminal Cover
and white information panel
Terminal Cover
AC Version with Terminal Cover
and black information panel
IMPORTANT: When attaching wiring to the green terminal connectors, use either solid wire or
stranded wire with wire ferrule(s) attached. Verify no loose strands are visible after
installation of wire ferrule(s).
• The green terminal block connectors are combination connectors, which allows you to
unplug the connector during the wiring process. Combination connectors can accommodate
between 12–24 AWG wire for your electrical connection
11

For DC Power:
7. Connect the DC power wires to the appropriate
terminals on the left.
• The + positive and - negative are clearly
marked on the sheet metal cover
• If you decide to use a 2-wire cable with shield for
the power supply connection, AMI provides
quality Shield Earth Ground Terminal Connection
next to the + positive and - negative terminals
For AC Power:
7. Connect the AC power wires to the appropriate
terminals on the left. The wire designations are
clearly marked on the black metal cover.
• H is for the Hot Wire
• N is for the Neutral Wire
• Position (A), as shown above, is for the AC Power
Ground
AC Power Ground
Terminal Connection (A)
Earth Ground
Terminal Connection
1st CONDUIT (POWER & ALARMS):
Protective Earth
Ground Lug
WARNING:
Analyzer must be connected to a Quality Protective Earth Ground for safety and the highest level of RFI
protection. This is accomplished by connecting an 16-gauge wire from the Analyzer's Protective Earth
Grounding Lug to an 8 foot ground rod or equivalent quality ground. (The Protective Earth Ground Lug is
located just below the explosion-proof housing as seen in the image above)
WARNING:
When using a AC power, never rely on the AC Power Ground as a source for Analyzer safety or ground
protection. Always connect the Protective Earth Ground Lug, shown above, to a high quality ground,
such as an 8 foot ground rod or equivalent.
12

IMPORTANT: IF YOU DESIRE TO USE THE ALARM CONTACT RELAYS, THE ALARM WIRES MUST BE PULLED
THROUGH THE SAME CONDUIT AS THE SUPPLY POWER.
RECOMMENDED: WHEN USING DC POWER, USE A SHIELDED-TWISTED PAIR CABLE AND CONNECT THE
CABLE SHIELD TO THE SHIELD EARTH GROUND TERMINAL SHOWN IN POSITION 'A' OF
THE ILLUSTRATION BELOW. DO NOT CONNECT THE OTHER END OF THE SHIELD WIRE AS IT
WILL CAUSE UNDESIRABLE GROUND LOOPS!
8. Connect the wires for the two fully adjustable alarm contact relays to their proper terminals.
Note: Both alarm relays are rated for 5A @115VAC or 24VDC.
(DC Power Version is shown for alarm wiring. The AC version will
be identical for alarms, analog output and RS-485 connections.)
A
IMPORTANT: The relay contacts act like a simple switch breaking only a single leg of the circuit. In
keeping with good electrical practices while wiring the alarm contacts, We suggest
SWITCH/BREAK THE HOT LEG only, NOT THE GROUND LEG OF YOUR CIRCUIT.
13

9. Last, connect the wires for RS485 communication to their proper terminals.
NOTE: Always use a twisted 2-conductor cable with shield. Never connect both ends of the shield
to both devices (Analyzer and other device) as it will cause ground loops. Connect the analog
output shield to the shield earth ground shown above.
2nd CONDUIT (ANALOG OUTPUTS & RS485 COMMUNICATION):
(DC Power Version is shown. Instructions are the same for the
AC Power Version)
(DC Power Version is shown. Instructions are the same for the
AC Power Version)
10. Verify all electrical connections and then turn on the source of power. The Analyzer will power-up and
the LCD will blink for a few seconds during power-up. You may see some LEDs blinking within the
explosion-proof housing and NEMA 4X box as this is normal during operation.
Analog Output should be connected using a twisted
2-conductor wire with shield
11. Once you have tested all electrical functions, pour approved potting compound into the electrical
seal-offs.
14

12. Press and hold the DOWN ARROW BUTTON until the 'PSI' indication on the LCD begins to blink
(this will take a few seconds).
INITIATION OF THE PRESSURE SENSOR
13. Then press the UP and DOWN ARROW BUTTONS until the pressure reading goes to a value
of '0.0 PSI'.
14. The LCD will revert back to operation mode in ~ 3 seconds when no buttons are pressed.
Up and Down
Arrow Buttons
Pressure Reading
IMPORTANT: YOU MUST CALIBRATE THE PRESSURE SENSOR READING TO 0.0 PRIOR TO ANY GAS
CONNECTIONS. THIS WILL CORRECT FOR ELEVATION VARIATIONS.
15

• Sample Gas Inlet Pressure: You must have a minimum pressure of 0.5 psig for gas to flow
through the Analyzer.
WARNING
The maximum allowable inlet pressure for safe operation is 150 psig. Sites, where gas
pressure exceeds 150 psig, require a pressure reducing regulator installed between the
pipeline tap and Analyzer.
CAUTION
When the sample gas is hot and wet, it could cause water to condense in the Sample Line
or Analyzer
• For best operation, we recommend installing an AMI Demister and Analyzer Guardian,
which can be purchased separately
— The vertically-mounted Demister is designed to quickly and effectively reduce sample
pipeline gas temperatures to ambient. The Demister rapidly cools warm, saturated gas,
causing the liquids to condense out and drain back into the pipeline without requiring
maintenance of other solutions, such as drip pots and coalescing filters
— The Analyzer Guardian mounts directly on top of the Demister. It uses a combination of a
hydrophobic/oleophobic membrane and perforated flexible stainless-steel disc that work in
tandem, creating a barrier against saturated/wet gas, liquid slugs and particulates commonly found
in pipeline gas.
— The Analyzer Guardian is designed to automatically shut-off gas flow to the gas analyzer when a
liquid slug occurs. Once the liquid slug passes, gas flow will resume.
• All gas connections will require using the supplied ferrule set, ¼" stainless steel compression
fittings and tubing
Key Points:
Part III: Gas Connections
Demister Analyzer Guardian
16

Exhaust Port
Span Gas Inlet Port
Sample Gas Inlet Port
THE MODEL 210BX has 3 gas connections on its right side.
STEPS
1. Take a deburred length of ¼" stainless steel tubing and slip it through the supplied compression
nut and ferrule set. Confirm that the ferrule properly orientated at one end, and connect it to the
SAMPLE GAS INLET PORT.
Make sure the ¼" stainless steel tubing slips all the way into the compression fitting until it
bottoms out. Tighten the compression nut with 1 & ¼ turns.
2. Connect the other end to the pipeline gas tab, pressure reducing regulator or an AMI Analyzer
Guardian with Demister.
17

3. Take another deburred length of ¼" stainless steel tubing and slip it through the supplied
compression nut and ferrule set. Confirm that the ferrule set is properly oriented and then
connect to the EXHAUST PORT.
Make sure the ¼ stainless steel tubing slips all the way into the compression fitting until it
bottoms out. Tighten the compression nut with 1 & ¼ turns.
4. Run the other open end of the ¼" stainless steel tubing to a safe vented area outside of the
meter building.
CAUTION
The EXHAUST LINE must run slightly downhill the entire way to a safe area to allow any
condensate to drain outside and not back into the Analyzer. If you must run the EXHAUST
LINE vertically through the ceiling, install a 'knock-out' pot to capture the liquid condensate
just prior to going vertical. This will prevent condensate from running back into the Analyzer.
View of the installation of the Analyzer with the
proper orientation of the LRP and Demister
18

INITIATION OF SAMPLE FLOW TO
THE ANALYZER
Metering Valve
3-way Selector Valve
(Sample/Span/Off)
1. Leak check the newly installed sample gas line. Rotate the 3-WAY SELECTOR VALVE to the
OFF position. Then pressurize the sample line to ~ 20 to 100 psig. Use a squeeze bottle of
SNOOP® or equivalent product and leak check every fitting from the SAMPLE GAS INLET
PORT back to the sample tap (note: bubble formations indicate a leak). DO NOT USE the
spray bottle as this technique produces bubbles and does not achieve the best results.
Metering Valve
This valve is located at the center of the 3-WAY SELECTOR VALVE and used for adjusting both sample
and span gas flow rates. Turning the knob clockwise decreases the flow, while rotating it counter-
clockwise increases the flowrate.
Flow Meter
CAUTION:
DO NOT OVERTIGHTEN THE METERING
VALVES or you will damage them. They
are not ON/OFF VALVES!
3-way Selector Valve
This valve selects what gas flows past the sensor. You can rotate this valve clockwise or counter-
clockwise. In the SAMPLE position, sample gas will flow past the sensor. In the SPAN position, span
gas from the connected cylinder will enter through the SPAN GAS INLET PORT and flow past the
sensor (note: this port is provided for periodic calibrations). In the OFF position, both SAMPLE GAS
INLET PORT and SPAN GAS INLET PORT are blocked, which prevents any gas flow.
STEPS
Flow Meter
The flow meter indicates the flow rate of either the sample or span gas through the Analyzer.
2. Rotate the 3-WAY SELECTOR VALVE to the SAMPLE position. Then, slowly adjust the
METERING VALVE until the FLOW METER reads ~ 1.0 SCFH.
3. Allow the sample gas to purge the tubing and Analyzer.
END OF INSTALLATION
19