GREEN INSTRUMENTS G36 User manual

G36
Oxygen Analyzer Manual
Document ID number.: 01245

Program Menu Structure
2
<
+/--
<
+/--
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Figure 1-1: Program Menu Structure of the G36 Oxygen Analyzer

G36Oxygen Analyzer
Version 2.11 - March 2022 3
Content
1INTRODUCTION 5
1.1 ABOUT THIS MANUAL 5
1.2 INQUIRIES AND FEEDBACK 6
1.3 ABOUT THE ANALYZER 6
2SPECIFICATIONS 8
3SAFETY ASPECTS 9
4CONTROL AT DELIVERY 11
5INSTALLATION &CONNECTIONS 12
5.1 WHERE TO INSTALL THE ANALYZER 12
5.2 ELECTRICAL CONNECTION 12
5.2.1 Power Supply 13
5.2.2 Sensor Connections - SEN 13
5.2.3 Relay Outputs –D-OUT 14
5.2.4 Input Connections –INPUT 16
5.2.5 Analog Output Connections –A-OUT 16
5.2.6 SD Card 16
5.2.7 Other Connections 18
6MENU STRUCTURE 19
6.1 MAIN MENU 19
6.2 GRAPH MENU 20
6.3 INFORMATION MENU 22
6.4 CALIBRATION MENU 22
6.5 TOOLS MENU 23
6.6 NAVIGATING THE MENU STRUCTURE 25
7CONFIGURATION &COMMISSIONING 26
7.1 SETTING OF BASIC DISPLAY PARAMETERS 26
7.2 SETTING OF ALARMS 27
7.3 SETTING OF ANALOG INPUTS 28
7.4 SETTING OF ANALOG OUTPUTS 29
7.4.1 Analog Output 1 29
7.4.2 Analog Output 2 31
7.5 BACK-FLUSHING &AUTO CALIBRATION 31
7.6 LOADING DEFAULT SETTINGS &FACTORY SETTINGS 33
7.7 COMMISSIONING OF THE ANALYZER 33
8CALIBRATION 34
8.1 CALIBRATION WITH KNOWN OXYGEN GASES 34
8.2 ARTIFICIAL CALIBRATION OF OXYGEN SIGNAL 36

Content
4
9ROUTINE MAINTENANCE 37
9.1 ANALYZER 37
9.2 CALIBRATION 37
9.3 SENSOR 37
9.4 GAS CONNECTION 38
10TROUBLESHOOTING 39
11SPARE PARTS 41
12APPENDIX 43
12.1 SETTING OF ANALOG INPUTS 43
TABLE OF FIGURES
FIGURE 1-1: PROGRAM MENU STRUCTURE OF THE G36 OXYGEN ANALYZER 2
FIGURE 1-1: SIMPLIFIED SCHEMATIC OF THE ZIRCONIA CELL 7
FIGURE 5-1:TERMINALS PC-BOARD -100 -230 VAC 14
FIGURE 6-1:THE G36 MAIN MENUAND FOUR FUNCTIONAL MENUS 19
FIGURE 6-2: HISTORY &SETTINGS 21
FIGURE 6-3: NAVIGATING THE MENU STRUCTURE 25
FIGURE 7-1: BASIC DISPLAY SETTINGS 26
FIGURE 7-2: SETTINGS OF ALARM LIMITS 27
FIGURE 7-3: SETTINGS OF ANALOG OUTPUT 1 29
FIGURE 7-4: SETTING OF BACK-FLUSHING 32
FIGURE 8-1: CALIBRATION MENU STRUCTURE &QUICK GUIDE 35
FIGURE 12-1: MAIN MENU IF BOTH ANALOG INPUTS ARE AGREED TO BE USED 43

G36Oxygen Analyzer
Version 2.11 - March 2022 5
1Introduction
1.1 About this Manual
This manual contains data and instructions for the installation, operation, and mainte-
nance of the G36Oxygen Analyzer.
The instructions have been made in general terms and do not take into consideration a
specific installation. The instructions & figures have been made in general terms and do
not take into consideration specific installations. The figures used in the manual are only
for general illustration purposes. As such, the instruction manual is designed only for the
G36 Oxygen Analyzer.
The instructions for the installation, operation, and maintenance of the complete analyz-
ing system including sampling board designed for the G36 Oxygen Analyzer by Green
Instruments A/S are provided in a separate manual.
The manual does not describe all possible situations but only the most common and
known situations and cannot replace the necessary education of the personnel. Should
situations not described in the manual occur, which cannot be solved in accordance with
normal known practice and good workmanship, the operator should contact Green In-
struments A/S for instructions.
Attention
Before operation, read all instructions and warnings within this manual and
associated documentation. Improper use may cause personal injury and/or damage
of equipment and may void the warranty. Green Instruments A/S disclaims any
responsibility for damage and/or injury caused by improper installation, use or
maintenance of the equipment
Green Instruments A/S reserves the right to minor alterations and improvements owing to
developments without being obliged to enter the corresponding changes in this manual.
Green Instruments A/S reserves the copyright of the manual. Without prior written per-
mission of Green Instruments A/S, the manual may not be copied and given to unauthor-
ized people.

Introduction
6
1.2 Inquiries and Feedback
All claims and inquiries for spare parts shall be addressed to Green Instruments A/S or
our distributors. In all correspondence, or when ordering spare parts, please carefully
state the equipment type and serial number, which can be found on the label on the
equipment.
Green Instruments A/S appreciates all feedback and suggestions for improvement. If any
questions appear or any discrepancies are found in this manual, kindly contact Green
Instruments:
Green InstrumentsA/S
Erhvervsparken 29
DK-9700 Brønderslev, Denmark
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.greeninstruments.com
1.3 About the Analyzer
The G36 Oxygen Analyzer continuously measures the content of oxygen with concentra-
tions up to 21.0%. The G36 Oxygen Analyzer can be used to measure the content of oxy-
gen in N2or CO2based inert gas, in stack gas, or in connection with exhaust gas recircu-
lation (EGR).
The G36 Oxygen Analyzer uses a zirconia sensor. The zirconium dioxide sensors have
long been established as industry standards. The G36 uses a new type of zirconia sensor,
which can be used in a wide range of applications.

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The most important element
of the sensor is the zirconia
cell. At high temperatures,
the oxygen ions can diffuse
through the zirconium diox-
ide membrane. When the
membrane is exposed to an
environment that contains
different amounts of oxygen
(e.g. the sensor internal refer-
ence gas on one side and
sample gas on the other), na-
ture seeks to balance itself,
and the transportation of ions
through the membrane will
generate an electrical charge.
Sample Gas
Reference Gas
Zirconium Dioxide Membrane
O2–
O2–
ZrO2
O2
O2
O2
O2
O2
O2
O2
O2
O2
V
e–e–
Figure 1-1: Simplified schematic of the zirconia cell
This charge depends on the amount of the passing oxygen ions i.e. the difference between
the oxygen levels in the sample gas and the reference gas. This voltage will be detected
and converted into a signal that is proportional to the oxygen concentration in the sample
gas. The signal will be processed in the analyzer and the oxygen concentration of the
sample gas will be shown in the display.
The G36 Oxygen Analyzer has CE and MED markings as well as DNV, Bureau Veritas,
and Lloyds Register Type Approvals.
Download all product certificates at https://greeninstruments.com/

Analyzer Specifications
8
2Specifications
G36 Analyzer
Analyzer Types
•Inert Gas O2Analyzer
•Stack Gas O2Analyzer
•EGR-O2Analyzer
Monitors O2content in inert gas (N2or CO2based)
Monitors O2content in stack gas
Monitors O2content in exhaust gas recirculation
Sensor types
Zirconia sensor type SEN1 or SEN9
Measurement range
0.0%…21.0% O2
Ambient temperature
–15°C …55°C
Ambient humidity
Up to 100% at all relevant temperatures
Power supply
100…230 VAC –50/60Hz
Power consumption
Max. 40 VA per analyzer –recommended fuse: 4 AT
Sample flow
0.2…8.0 l/m
Sample temperature
SEN1: ≤ 250oC; SEN9: ≤ 650oC
Sample pressure
SEN1: max.1 bar; SEN9: max. 4 bar
Digital display
Touch screen 71 x 39 mm
Output signals
Active 4…20 mA – range selectable –default 0.0…25.0%
Load output (max.)
600 ohm/24 VDC
Relays
4 relays, volt free, 24 V AC/DC, 5 A
Alarm functions
Low or High O2level –set points freely configurable
High-High O2level –set point freely configurable
System failure alarm
Response time*
90% of measuring scale in less than 45 sec. with sample flow
rate of 0.8 l/m, sample line of 1 m
Repeatability
+/–0.1% of the measuring range
Linearity/Accuracy
+/–0.5% of the measuring range
Drift (one month)
+/–0.1% of the measuring range
Dimensions
17 × 20 × 9 cm (H×W×D)
Weight (analyzer only)
2.5 kg without packaging
Analyzer casing
Aluminum casing IP67
Optional: O2 analyzer with pressure compensation module, BV’s product certificate.
Specifications are subject to changes without notice.
* Response time depends on the sample flow rate and the length of the sample line.

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3Safety Aspects
Attention
•Follow the operating instructions!
•Make sure that all power and signal cables are connected correctly before
operating the analyzer.
•The sensor and sensor housing are hot and can cause severe burning of
personnel if not handled with care.
•The G36 Oxygen Analyzer is only suitable for installation in a safe, non-
hazardous area and not suitable for use with flammable sample gases.
•It should be pointed out that installation and operation of the G36 Oxygen
Analyzer and associated equipment must be carried out by skilled, trained,
and certified personnel, and that Green Instruments A/S does not take any
responsibility for the operation of the analyzer and associated equipment
whatsoever.
•The analyzer must only be applied as described in this instruction manual. If
the analyzer is used in a manner not specified by Green Instruments, the
protection provided by the analyzer may be impaired.
•Successful and safe operation of this equipment depends on proper handling,
installation, operation, and maintenance.
Hazardous voltage!
Always disconnect power before installing or servicing the analyzer. Ignoring this warn-
ing can result in severe personal injury or material damage. Read the instruction carefully
to ensure correct connection of all power and signal leads. Make sure that the correct
voltage is connected to the analyzer (see rating marked on the analyzer name plate).
Circuit breaker!
The installation must include a way to switch off the electrical power by a clearly marked
switch or circuit breaker external to the analyzer. The external switch or circuit breaker
shall be placed in close proximity to the analyzer and within easy reach of the operator.
Overload protection!
For compliance with the IEC 61010-1 (2003) safety requirements, the installation must
include a means of overcurrent protection to provide protection against excessive energy
being drawn from the power supply system in case of a fault in the analyzer.

Safety Aspects
10
Protective earth!
The analyzer must be connected to protective earth.
Installation and fault finding!
Electrical installation and fault finding on the analyzer should only be undertaken by a
suitably trained and qualified engineer.
EMC!
For compliance with the EMC product standard IEC 60533 (1999), the connection cables
for the main supply, relays, interface, and analog output signals should be shielded or
provided with equivalent protection.
Special precautions have to be taken in connection to "long" signals or control lines of
more than 30 meter.
Sensor!
The sensor must not be exposed to strong mechanical shocks. Otherwise the sensor ele-
ment may crack without visible damage.
The sensor must be connected to the analyzer before the analyzer is powered up (risk of
damage). As soon as the analyzer is under voltage, the connection to the sensor must not
be interrupted. Therefore, please disconnect the power when you need to connect or dis-
connect the sensor.
Connections!
All electrical connections and power supplies are placed inside the analyzer. To gain ac-
cess, unbolt the top cover of the analyzer using a standard 4-6 mm screwdriver.
Poisonous gases!
Both sensor types, SEN1 and SEN9, used for the G36 Oxygen Analyzer are not suitable
for installation in areas with a high concentration of methane (CH4).
Besides, a reduced life time can occur if the sensor is subjected to lead, phosphor, silicon,
halogens or high concentration of sulfur.
Recycling!
Please do not dispose the G36 Oxygen Analyzer with regular refuse. Disposal should be in
accordance with the requirements of the current statutory regulations.
Symbol identification
Caution, risk of danger
Caution, hot surface
Caution, risk of electrical shock
Protective earth
The CE mark proves the compliance of the instrument with the requirements of
the relevant EU directives