Eaton Crouse-hinds series User manual

G1010 MkII
MTL oxygen analysers
January 2017
INM MTL 130-0116 Rev 14
Instruction manual
MTL gas analysers & systems

ii INM MTL 130-0116 Rev 14
DECLARATION OF CONFORMITY
A printed version of the Declaration of Conformity has been provided separately within the original shipment of
goods. However, you can find a copy of the latest version at -
http://www.mtl-inst.com/certificates

INM MTL 130-0116 Rev 14 iii
CONTENTS
DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
1 INTRODUCTION ....................................................................1
1.1 Manual symbols ...........................................................................1
1.2 Information ...............................................................................1
2 SPECIFICATION.....................................................................2
2.1 Display...................................................................................2
2.2 Display and output ranges G1010 and G1010R ..................................................2
2.3 Stability ..................................................................................2
2.4 Cell life...................................................................................2
2.5 Sample flow ..............................................................................2
2.6 Sample pressure...........................................................................2
2.7 Sample temperature .......................................................................3
2.8 Sample connections........................................................................3
2.9 Speed of response .........................................................................3
2.10 Analogue output...........................................................................3
2.11 Alarm outputs .............................................................................3
2.12 Environmental conditions ...................................................................3
2.13 Supply voltage ............................................................................3
2.14 Mounting.................................................................................3
2.15 Dimensions ...............................................................................3
3 INSTALLATION .....................................................................4
3.1 Unpacking and visual checking...............................................................4
3.2 Mounting.................................................................................4
3.3 Power supply .............................................................................4
3.4 Connections ..............................................................................4
3.5 Sample connections........................................................................5
3.6 Cell characteristics .........................................................................9
3.7 Cell installation ...........................................................................10
3.8 Alarm contacts ...........................................................................10
3.9 Mounting and connecting remote sensor version ..............................................10
4 COMMISSIONING .................................................................11
4.1 Applying power ..........................................................................11
4.2 Programming ............................................................................11
4.3 Applying the sample ......................................................................12
4.4 Error messages...........................................................................13
5 MAINTENANCE AND CALIBRATION CHECKS ...........................................15
5.1 Typical cell life ...........................................................................15
5.2 Calibration...............................................................................15
5.3 Cell replacement - overview ................................................................18
6 SPARES AND REPAIRS..............................................................20
6.1 Ordering parts............................................................................20
6.2 Storage of measuring cell ..................................................................20
6.3 Product- end of life .......................................................................20

iv INM MTL 130-0116 Rev 14
THIS PAGE IS LEFT INTENTIONALLY BLANK

INM MTL 130-0116 Rev 14 1
1 INTRODUCTION
The Oxygen Analysers in this range are microprocessor controlled and provide a performance
and a range of features without parallel for analysers of this type and cost.
The G1010 and G1010R have a display that autoranges over a span of approximately 5 decades,
(depending on the model) the alarms and analogue output are user programmable.
The G1010Tx and G1010TxX have fixed display and analogue output ranges.
The G1010Tx , TxX and R comprise of two parts; a panel mounting electronic control-display
unit and a remote sensor-transmitter unit. The two are linked by a two-core cable and, by
incorporating a zener barrier in the two wire connection (the G1010TxX version), the sensor unit
can be mounted in a hazardous area.
Depending on the range and application, one of four types of oxygen sensor is fitted. In
this way concentrations from 100% to a few ppm can be monitored in a broad spectrum of
applications.
1.1 Manual symbols
The following methods are used in this manual to alert the user to important information:-
WARNING
Warnings are provided to ensure operator safety and MUST be followed.
CAUTION
A Caution is provided to prevent damage to the instrument.
NOTE
These are used to give general information to ensure correct operation
1.2 Information
Waste Electrical and Electronic Equipment directive (WEEE) 2002/96/EC
(RoHS) directive 2002/95/EC
WARNING
This equipment must only be used in accordance with the
manufacturer’s specification, instructions for installation, use and
maintenance to ensure that the protection of the operator is not
impaired. It is the responsibility of the installer to ensure the safety and
EMC compliance of any particular installation.

2INM MTL 130-0116 Rev 14
2 SPECIFICATION
2.1 Display
Multi-digit LCD- character height 12.7mm
2.2 Display and output ranges G1010 and G1010R
1. E cell model - Display range 0.1% to 100.0%. Resolution: 0.1% from 10% to
100%; 0.01% below 10%.
2. N cell model - Display range 100ppm to 50%. Resolution: 0.1% from 10% to
50%; 0.01% from 0.50% to 9.99%; 10ppm from 500ppm to 4999ppm;
1ppm from 0ppm to 499ppm
3. H cell model - Display range 10ppm to 10%. Resolution: 0.01% from 0.50%
to 9.99%; 10ppm from 500ppm to 4999ppm; 1ppm from 50ppm to 499ppm;
0.1ppm from 0.0ppm to 49.9ppm
4. L cell model - Display range 1ppm to 10%. Resolution: 0.01% from 0.50% to
9.99%; 10ppm from 500ppm to 4999ppm; 1ppm from 50ppm to 499ppm;
0.1ppm from 0.0ppm to 49.9ppm
G1010 Tx &TxX
These are cell dependent and factory set.
1. E cell - Ranges available: 0/100%, 0/25% and 0/5%. Display resolution: 0.1%
for 25% & 100%; 0.01% for 5% range
2. N cell - Ranges available: 0/25%, 0/5%, 0/5000ppm, Display resolution: 0.1%
for 25.0%; 0.01% for 5% 10ppm for 5000ppm
3. L cell - Ranges available: 0/5000ppm, 0/500ppm, 0/50ppm Display
resolution: 10ppm for 5000ppm; 1ppm for 500ppm; 0.1ppm for 50ppm
4. H cell - Ranges available: 0 to 5000ppm, 0 to 500ppm.
Display resolution: 10ppm for 5000ppm; 1ppm for 500ppm.
2.3 Stability
Better than 2% of reading per month, or 1ppm whichever is greater.
2.4 Cell life
1. E cell- up to 5 years- Suitable for samples containing mildly acidic gases. e.g.
carbon dioxide, hydrogen sulphide etc.
2. N cell- up to 2 years- Suitable for inert background gases. The output is not
affected by normal changes in atmospheric pressure
3. L cell- up to 2 years- Suitable for inert background gases. The output is not
affected by normal changes in atmospheric pressure
4. H cell- up to 2 years-Special cell used for samples containing hydrogen. The
output is not affected by normal changes in atmospheric pressure
2.5 Sample flow
Between 100 and 300 ml/min for optimum operation. Max. 1 l/min
2.6 Sample pressure
The pressure applied to the cell is determined by the vent pressure which should be
atmospheric for quoted accuracy.
NOTE
The sensor must not be subjected to rapid pressure changes.

INM MTL 130-0116 Rev 14 3
2.7 Sample temperature
–5 to +40°C (non condensing)
2.8 Sample connections
Inlet and outlet: captive seal compression fittings suitable for 0.25 inch (or 6mm)
o/d tube
2.9 Speed of response
T90 is variable depending on sensor and concentration and is approximately 3 secs
at % levels and 20 secs at ppm levels. The ppm figure assumes that the sensor is
purged down.
2.10 Analogue output
0 to 5 volts (min. load 10k ohms) or 4 to 20mA (max. load 300 ohms)
Isolation: max. 30V ac 70Vdc
The 20mA point oxygen value for G1010Tx and G1010TxX are fixed to the
instruments display range. The G1010 and G1010R are user programmable over the
following ranges.
‘E’ Type cell: 5% to 100%
‘N’ Type cell: 50ppm to 50%
‘L’ & ‘H’ Type cell: 50ppm to 10%
Setting resolution
0.1% from 10.0% to 100%
0.01% from 0.50% to 10.0%
10ppm from 500ppm to 4999ppm
1ppm from 50ppm to 499ppm
2.11 Alarm outputs
2 alarms, each user-programmable for mode - HIGH, LOW or OFF;
Level - over full display range of instrument and hysteresis - 0% to 10% of set point.
Volt free c/o contacts rated at 30V AC or DC, 1A, normally energised.
2.12 Environmental conditions
Temperature: 0 to 40°C - continuous
–5 to + 50°C - intermittent
Altitude limit: < 2000 metres
Humidity: RH < 80% non condensing
Pollution degree: Pollution degree 2
2.13 Supply voltage
110/120V or 220/240V AC, 50/60 Hz. Max. power consumption 10VA
Class 1 equipment
24V DC, ±10% including ripple and noise. Max. power consumption 6W
2.14 Mounting
Panel-mounting with two clamps
Enclosure material: Glass-fibre reinforced Noryl.
Protection level: When panel mounted (rear of instrument not exposed) IP40, or
IP54 with optional clear lockable door. IP30 otherwise.
2.15 Dimensions
See Figures 1 (page 4) and 4 (page 7).
Where relevant, performance figures are quoted under NTP conditions i.e. 20°C (68°F) at 1
atmosphere pressure.

4INM MTL 130-0116 Rev 14
3 INSTALLATION
3.1 Unpacking and visual checking
Take all standard precautions when opening packages. In particular avoid the use of
long bladed cutters. Search packing before discarding it and make sure that all of the
components are removed. Check that all pipe connections have captive seal nuts.
3.2 Mounting
Chose a site where the ambient temperature will remain between the limits of the
instrument (see “Environmental conditions” on page 3), and where the analyser
will not be subjected to vibration, knocks or jolts. It may be tilted etc. in any attitude.
To install the electronic control/display unit, remove the screw side-clips (if fitted)
and slide the unit into the panel cut-out. Re-fit the two clips and tighten them up.
See Figure 1 for dimensional details.
Figure 1 - Instrument dimensions
3.3 Power supply
The standard options are 240V AC, 110V AC or 24V DC. Refer to the serial number
plate located on the side of the instrument for details.
3.4 Connections
WARNING
This instrument must be installed with a disconnecting switch close
to it, within easy reach of the operator and compliant with the relevant
parts of IEC 60947-1 and IEC 60947-3. It must be marked to indicate this
function and show ON and OFF positions. Wiring should conform to
local codes.
Only the live conductor has an internal equipment fuse.
All electrical connections are via a plug-in terminal block on the rear panel. Terminal
identity as shown in Figure 2.
See Fig 3, 4 & 5 for details of optional remote sensor version.
Note: N/C = Normally closed N/O = Normally open
NOTE
The Relay operation and labelling ‘Normal’ relate to “process normal” and not the
electrical rest position of the relays.
In process normal the relays are energised.
Analyser with integral cell
196mm
165mm
96mm
Mounting Clamp - both sides
92mm
92mm +0.8/-0.0
+0.8/
-0.0
Mounting Aperture

INM MTL 130-0116 Rev 14 5
Figure 2 - Instrument connections
3.4.1 Installation requirements for EMC
To ensure compliance with the European EMC directive, certain installation
precautions are necessary as detailed here.
3.4.1.1 Routing of wires
To minimise the pick-up of electrical noise all signal wiring should be shielded and
routed away from power cables.
3.5 Sample connections
The standard sample connections are shown in Figures 3, 4 & 5 that follow. It is
important that the gas sample being supplied to the analyser is clean and non-
corrosive. Filters or chemical absorbers will be necessary for those samples that
contain particulate matter or corrosive components. Additionally the dew-point of
the sample should not be above the ambient temperature.
If site or process conditions require that the process is isolated from the analyser
when the cell is changed then shut-off valves should be fitted to the inlet and outlet
of the measuring cell. The inclusion of a three way valve on the inlet side can also
be used to allow easy connection of a standard gas for calibration checks. It is
particularly important that good pipework connections are made when low levels of
oxygen are being measured.
For all parts per million (ppm) measurements the pipework up to the inlet of the
measuring cell, should be all metal or hard plastic such as Nylon 6, un-plasticised
P.V.C. etc.; PTFE, plasticised P.V.C. and other soft plastics ARE NOT SUITABLE.
Flowmeters and pumps must be suitable for handling ppm levels if placed on the
inlet to the cell. The cell is shipped with its inlet tube plugged, DO NOT REMOVE
THE PLUG until you are ready to fit the cell to the instrument. This is particularly
important for instruments fitted with L cells, irrespective of the positioning of flow
meters etc.
It is important to fit a pipe of at least 300mm length to the sample vent/outlet
connection to prevent back diffusion of air. It should be noted that back diffusion
can occur even when the sample is flowing, and is due to the difference in oxygen
partial pressure between the sample and air. The pipe should be short enough and
of sufficient bore to prevent significant back pressure when the sample is flowing.
Standard 6mm or ¼” tubing is ideal.
CAUTION
The cell must not be pressurised beyond ± 0.25 bar gauge.
Rapid pressure changes could damage the cell, and pulsation will give an erratic display.
12345678910
-++ -CNC NO C NC NO
Cell An. O/P Alarm 1 Alarm 2 Mains
11 12 13
NEL
120-0023
DC
11 12 13
-E+
120-0024
12
+-
Tx
OR
OR
12
+-
Tx
OR

6INM MTL 130-0116 Rev 14
Figure 3 - G1010 sampling system