GREEN INSTRUMENTS G3610 User manual

PART NUMBER.: 01599
GAS SAMPLING BOARDS FOR N2
GENERATORS FOR G3610/G3611

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G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 3
Content
1INTRODUCTION 5
1.1 ABOUT THIS MANUAL 5
1.2 INQUIRIES AND FEEDBACK 6
2SPECIFICATIONS 7
3INSTALLATION 8
3.1 CONTROLAT DELIVERY 8
3.2 WHERE TO INSTALL THE SYSTEM 8
3.3 SAFETY ASPECTS 9
3.4 SAMPLING BOARD 9
3.4.1 Mounting Panel 9
3.4.2 Gas Connection 10
3.4.3 Vent Line Connection 12
3.4.4 Analyzer and Electrical Connection 12
3.4.5 Digital Flow Switch (Optional) 12
3.4.6 Sensor Connection for the G36p Panel Mounted Analyzer 12
4COMMISSIONING 15
4.1 INSTALLATION CHECKS OF THE SAMPLING BOARD 15
4.2 COMMISSIONING OF THE ANALYZER 15
4.3 STARTING THE SYSTEM 15
5ROUTINE MAINTENANCE 17
5.1 SAMPLING SYSTEM 17
5.2 ANALYZER 17
6SPARE PARTS 18
TABLE OF FIGURES
FIGURE 3-1: P&ID OF THE G3610A WITH OXYGEN ANALYZER MOUNTED ON BOARD 10
FIGURE 3-2: P&ID OF THE G3611P WITH SEPARATE G36POXYGEN ANALYZER 11
FIGURE 3-3: N2N -NARROW SAMPLING BOARD WITHOUTANALYZER 13
FIGURE 3-4: N2W –WIDE SAMPLING BOARD WITH G36AOXYGEN ANALYZER 14

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G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 5
1 Introduction
1.1 About this Manual
This manual contains data and instructions for the installation, operation, and
maintenance of the Green Instruments gas sampling boards for nitrogen genera-
tors:
G3610a N2W board 100-230 VAC –wide
G3612a N2W board 100-230 VAC –wide with flow alarm
G3611p N2N board 24 VDC –narrow
G3613p N2N board 24 VDC –narrow with flow alarm
Other system may be added at a later stage.
The sampling boards can be combined with the G36a Oxygen Analyzer or the G36p
Oxygen Analyzer panel mounted. One sampling board and one analyzer forms a
complete oxygen analyzing system for nitrogen generators, hereafter named a
NGOA System.
The instructions for installation, operation, and maintenance of the analyzers are
provided in separate manuals:
the G36aOxygen Analyzer manual (p#01245)
the G36pOxygen Analyzer manual (p#01381)
Therefore, for the installation, operation, and maintenance of an entire NGOA
System, this manual and the concerned oxygen analyzer manual must be read
carefully in their entirety.
The instructions have been made in general terms and do not take into considera-
tion the existing equipment of the nitrogen generator and its installation. As such,
this manual is designed for the standard Green Instruments NGOASystem.
This manual does not describe all possible situations but only the most common
and known situations. It cannot replace the necessary education and training of the
personnel.

Introduction
6
Should situations not described in this manual occur that cannot be solved in ac-
cordance with normal known practice and good workmanship, the operator should
contact Green Instruments A/S for instructions.
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 this manual. Without prior writ-
ten permission of Green Instruments A/S, the manual may not be copied and given
to unauthorized people.
1.2 Inquiries and Feedback
All claims and inquiries for spares 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 fabrication number which you can find on the back of the
G36p OxygenAnalyzer or on the right side of the G36a Oxygen Analyzer.
Green Instruments A/S appreciates all feedback and suggestions for improvement.
If you have any questions or find any errors in the manual, you are welcome to
contact us at the following address:
Green Instruments A/S
Erhvervsparken 29
DK-9700 Brønderslev
Denmark
Phone:
Fax:
[phone]
[phone]
E-mail:
Web:
[e-mail]
www.greeninstruments.com

G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 7
2 Specifications
Sampling Board for Nitrogen Generator
Sample pressure
Minimum 4 bar –maximum 10 bar on all inlet ports –pref-
erably constant and identical pressure on all inlet ports.
Sample flow
1–5 l/m.
Sample temperature
0 °C to 70 °C.
Sample manifold
3 sample/test gas ports –1/8” BSP connection.
1 port for vent line connection - 1/8” BSP connection.
Selector valve
5-way and 3-position switching valve SS 316.
Narrow board dimension
Dimensions: 60 × 30 × 14 cm (H × W × D).
Weight: Approx. 7.5 kg without analyzer and packaging.
Wide board dimension
Dimensions: 60 × 50 × 14 cm (H × W × D).
Weight: Approx. 9.0 kg without analyzer and packaging.
Analyzer
See details in the oxygen analyzer manual chapter 2.
Optional Equipment
Digital flow switch
0.2–10.0 l/min, 1 analog output 4–20 mA & 1 NPN output,
display with LED type 3 digits, 1 alarm set point with the
NPN output.
Other optional equipment
Pre-filter for sample gas, signal amplifier, signal amplifier
for logarithmic output, remote digital display, visualization,
recording, and data logging.
Specifications are subject to changes without notice.

Installation
8
3 Installation
Read this chapter in its entirety before installing the system.
3.1 Control at Delivery
When you receive the shipment, please inspect and confirm that the received
scope of supply is in accordance with the packing list and not damaged. Any dis-
crepancy should be reported to the supplier immediately. If any of the received
parts are damaged, the shipping company should be informed, and new parts
should be made available before completing the installation.
3.2 Where to Install the System
Satisfactory operation, faultless functions, and minimal maintenance of the sam-
pling board, are achieved by paying attention to the following points:
The sampling board should be installed in a clean area away from dust, oil
mist, and moisture. The elements of the system shall be installed at viewing
level so that they are easy to access in connection with operation and service.
It is recommended that the sampling board is located very close to the sam-
pling point of the nitrogen generator in order to obtain current and accurate
readings. Large bore sample lines as well as longer sample lines will increase
the response time due to dead volume.
The best results are achieved with constant and identical pressure on all incom-
ing ports between 4…10 bar.
The panel mounted analyzer G36p can be installed up to 6 m from the sampling
board.
For details about the installation of the analyzer, please see section 3.2 in the ana-
lyzer manual.

G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 9
3.3 Safety Aspects
Hot sensor
The sensor is hot and can cause severe burning of personnel if not handled with
care.
Analyzer
Before working with the analyzer, please read the oxygen analyzer manual in its
entirety.
Installation and operation
It should be pointed out that installation and operation of the sampling board for
nitrogen generators and associated equipment must be carried out by skilled,
trained, and certified personnel, and that Green Instruments A/S does not take any
responsibility of the operation of the system and associated equipment whatsoev-
er.
The successful and safe operation of this equipment is dependent upon proper
handling, installation, operation, and maintenance.
Recycling
Do not dispose any part of the sampling board with regular refuse. Disposal
should be in accordance with the requirements of the current statutory regulations.
3.4 Sampling Board
The sampling boards are designed for mounting with the G36pOxygen Analyzer
panel mounted version or the G36aOxygen Analyzer.
3.4.1 Mounting Panel
The mounting panel has two angle iron mounting brackets. The brackets are made
of ordinary mild steel and can be welded or bolted directly to a chosen structure as
required. The two mounting brackets are mounted horizontal and parallel with a
distance of 550 mm. See Figure 3-3 for the dimensions and layout of the narrow
board and Figure 3-4 for the wide sampling board.
The sampling board needs to be installed as close as possible to the nitrogen gas
supply line in order to reduce dead time of test gas flowing through the piping
(see section 3.2). When the sampling board is installed in an appropriate location,
the sample gas, calibration gas, and power are connected as described below.

Installation
10
3.4.2 Gas Connection
The connections for the gas lines are located in the upper left corner of the system
board at the manifold. It is possible to connect up to three samples. The three con-
nections are all arranged as 1/8" BSP female connections, and are marked from
the bottom: 1, 2, and 3. The system is supplied with the sample ports plugged.
Green Instruments A/S advises the following arrangements of gas connection:
Port 1 (bottom) sample line from the nitrogen generator
Port 2 (middle): span calibration gas (typically clean dry instrument air)
Port 3 (top): zero calibration gas with a known oxygen concentration
Valve
00358
Filter
Regulator
00657
Sensor
01258
Flow
Meter
00839
GI supply
Power supply
See rating
Cable dia. 11-14 mm
Signal outputs
4...20 mA
Cable dia. 6-8 mm
GI supply
GI supply
GI supply
G36a Oxygen Analyzer
(Specification in a
separate manual)
Flow
5
For acurate measurements the following
requirement must be met:
Minimum 4 bar and maximum 10 bar
pressure on all three ports.
The best result is achieved with identical
and constant pressure on all three ports.
Vent Line –1/8" BSP
Port 1 –1/8" BSP
Port 2 –1/8" BSP
Port 3 –1/8" BSP
Figure 3-1: P&ID of the G3610a with oxygen analyzer mounted on board

G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 11
Valve
00358
Filter
regulator
00657
Connector
01438
Sensor
01258
Flow
Meter
00839
GI supply
Power supply
24 VDC
Cable dia. 11-14 mm
Signal outputs
4...20 mA
Cable dia. 6-8 mm
GI supply
GI supply
GI supply
G36p Oxygen Analyzer
(Specification in a
separate manual)
Flow
5
For acurate measurements the following
requirement must be met:
Minimum 4 bar and maximum 10 bar
pressure on all three ports.
The best result is achieved with identical
and constant pressure on all three ports.
Cable
00457
Vent Line –1/8" BSP
Port 1 –1/8" BSP
Port 2 –1/8" BSP
Port 3 –1/8" BSP
Figure 3-2: P&ID of the G3611p with separate G36pOxygen Analyzer
The sample gas has to be extracted from a suitable location that represents the gas
to be tested.
Calibration gases are typically clean and dry instrument air as span gas (i.e. with
20.9% oxygen) and a test gas bottle as zero gas (typically in the range of 0% to
5% oxygen). The zero gas should be chosen so that the concentration is just under
the targeted O2concentration of the nitrogen generator.

Installation
12
The pressure and flow rate of the calibration gasses should be the same as the
pressure and flow rate from the sample line under normal operating conditions of
the nitrogen generator. Please keep the inlet pressure as even and identical on all
inlet ports as possible.
3.4.3 Vent Line Connection
The vent line connection for the sensor house is placed right below the sample
ports. It is used to connect an external vent line which allows venting the sam-
ple/test gases going through the sensor to the outside air. The vent line must be
dimensioned to allow a gas flow of at least 10 l/min and arranged in such a way
that it avoids backpressure and secures a sufficient gas flow. The vent line must be
uninterrupted and easily remove the sample/test gases.
3.4.4 Analyzer and Electrical Connection
The instructions for the electrical connections of the analyzer are described in sec-
tion 3.4 in the analyzer manual.
3.4.5 Digital Flow Switch (Optional)
If the sampling board is configured with a digital flow switch, please see the en-
closed leaflet for installation and operating instructions.
3.4.6 Sensor Connection for the G36pPanel Mounted Analyzer
The panel mounted analyzer is connected to the sampling board by a sensor cable.
The sensor connection is arranged below the vent line connection. For details,
please see item number 2 in Figure 3-3.

G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 13
125
550
Mild steel support brackets f. bolting or welding
154 234
40
1
2
5
4
21
3
600
290
74
280
37
54
97
160
45
Connector f. sensor cable.
General tolerances acc. to DIN 7168sg
Sample 3 Sample 2 Sample 1 Vent Line
1
1/8"BSP F All pi pe conn.
101258SEN9 Oxygen Sensor /w connector 1
ITEM NO. PART NUMBER DESCRIPTION QTY.
500358Selector valve sample/test gases 1 400657Filter Regulator 1/8", 0-2 bar SMC 1 300839Flow meter 0,5-5l/min, w, contr. v. 1 201438
1/13/2010
1 OF 1
01440
Gas Sampling Board for Nitrogen Generator N2n – narrow – analyzer to be mounted separately
1:5
OS
1/13/2010
permission of Green Instruments A/S
* THIS IS A CAD DRAWING AND MUST NOT BE CORRECTED BY HAND *
Department:
Drawn: Materiale Drawing No:
Weight:
Approv: Page
Scale
PR
The ownership to and the contents of this document are proctected under Danish Law. The document or the contents thereof must not be made known, copied or otherwise used without the written
GI
Figure 3-3: N2n - narrow sampling board without analyzer

Installation
14
126
550
5
4
2 31
General tolerances acc. to DIN 7168sg
600
500
Sample 3 Sample 2 Sample 1 Vent Line
1/8" BSP F All pipe conn.
SEN9 Oxygen Sensor /w connector 01258
51 41Selecector valve sample/test gases 00358 31Flow Meter 0.5-5.0 l/m w. contr. v. 00839 21Filter Regulator 1/8", 0-2 bar SMC 00657 11H36 Oxygen Analyzer 100-230VAC 01482
Item No. QTY Desription GI Part no.
N 2 w b o a rd 1 0 0 -2 3 0 V A C
O S
1 O F 1
1 :5
G I
3/2/2010
p e rm i ss io n o f G r e e n I n stru m e n ts A / S
* T H IS IS A C A D D R A W IN G A N D M U S T N O T B E C O R R E C T ED B Y H A N D *
D e p a r tm e n t:
D ra w n: M a te ria le D ra w ing N o :
W e ig h t:
A p p r o v :
P a g e
S c a l e
01498
P R 3/2/2010
T h e o w n e r sh ip t o a n d th e c o n te n t s o f t h is d o c u m e n t a r e p r o cte c te d unde r D a n i sh L a w . T h e d o c u m e n t o r th e c o n te n t s t h e re o f m u s t n o t b e m a d e k n o w n , c o p ie d o r o t h e rw i se u s e d w i th o u t th e w ri tt e n
N itr ogen A n a l yz in g S y s te m
160
37
54
74
97
45
Mild Steel brackets f. bolting or welding
440 360
12
12
Figure 3-4: N2w –wide sampling board with G36a Oxygen Analyzer

G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 15
4 Commissioning
Before starting the system for the first time after completing the in-
stallation, please check the installation of the system.
4.1 Installation Checks of the Sampling Board
Check that the span and zero calibration gases are connected and that all con-
nections are secured and not leaking. A leaking connection will result in loss
of calibration gas and may result in poor calibration.
Check that the sample gas line is connected and that the connections are se-
cured and not leaking. The sample gas connection should be as close to the
process as possible, preferably made from 6 mm stainless piping in order to re-
duce the dead volume in the sampling system. If the sample gas is heavily con-
taminated with particles, a pre-filter should be installed. The sample gas has to
be extracted from a suitable location that represents the gas to be tested.
Check the pressure and flow rate of the calibration gasses which should be the
same as the pressure and flow rate from the sample line under normal operating
conditions of the nitrogen generator. Please keep the inlet pressure as even and
identical on all inlet ports as possible.
4.2 Commissioning of the Analyzer
Check the connection and settings of the analyzer by following the instructions
in chapter 3 to 5 in the analyzer manual.
4.3 Starting the System
Start the analyzer by following the instructions in chapter 5 in the oxygen analyzer
manual. Then, follow the instructions below.
Introduce the sample gas to the sensor by turning the selector valve to the cor-
rect position.

Commissioning
16
Check the gas pressure at the pressure regulator. It is preset and locked to 0.03
MPa (≈ 0.3 bar). It might swing ± 0.01 MPA (≈ 0.1 bar).
Adjust the flow to approximately 1–2 l/m. If the flow is too high (i.e. >5 l/m)
the sensor temperature will change and consequently the readings.
Calibration can be performed when the sensor temperature reaches normal operat-
ing temperature, and the indication has stabilized. This normally happens about 5–
10 minutes after starting the system.
Now, the system is ready for calibration following the instructions in chapter 6 in
the oxygen analyzer manual.

G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 17
5 Routine Maintenance
5.1 Sampling System
Routine inspection and maintenance of the sampling system is required to make
sure no gas is leaking from the test or calibration gas supply. Failure to periodical-
ly inspect and maintain the above requirements may lead to imprecise analyzer
readings and thus a malfunction of the nitrogen generator.
The system, including flow control valves and the sample and test gas selector
valves, is tested from the factory.
For the selector valve packing, adjustment may be required for a leak-tight per-
formance. Adjust the packing by turning the packing bolt clockwise in 1/16-turn
increments until leak-tight performance is achieved. Always verify proper opera-
tion upon installation.
Protect the reduction units from the ultraviolet rays and adhesion of organic sol-
vents. Depressurize the reduction stations before cleaning and service.
Clean with neutral detergent.
5.2 Analyzer
See chapter 7 in the analyzer manual for routine maintenance of the analyzer.

Spare Parts
18
6 Spare Parts
When ordering spare parts, please quote the serial number of the an-
alyzer which you can find on the label on the back of the G36p analyz-
er and on the right side of the blue G36a analyzer box.
Part
No.
Part Description
the specific appearance of the spare
parts is subject change without notice;
the function however will not change
00358
Selector valve sample/test gases
00457
Sensor cable –3.0 m
w. female & male connectors
00657
Filter regulator –1/8”, 0–2 bar
00839
Flow meter 0.5-5.0 l/m w. control valve
01047
Cable gland –M20 (11-14 mm)

G3610/G3611 Gas Sampling Boards for N2Generators
Version 1.0 –August 2019 19
Part
No.
Part Description
the specific appearance of the spare
parts is subject change without notice;
the function however will not change
01241
G36aOxygen Analyzer 100-230 VAC
01245
G36a Oxygen Analyzer manual
01251
Fuse 2 AT (pkg of 10)
01258
SEN9 oxygen sensor/w connector –screw type
01381
G36pOxygen Analyzer manual
01382
G36p Oxygen Analyzer Panel 24 VDC
(includes 01388)
01388
Gasket for panel mounted analyzer
01434
Panel feed through, M12, 5 poles

Spare Parts
20
01471
SD card with software & standard settings files –
please quote the serial number of the analyzer
when you order an SD card.
01599
This manual
Optional
01453
Digital flow switch 0.2-10 l/min (optional)
Other optional equipment e.g. visualization, recording and data logging, monitor-
ing of gas temperature, pressure, and load.