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AMI Watchdog Manual

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AMI
Oxygen Analyzer Manual
"Watchdog"
AMI, Costa Mesa, CA

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  • Page 1 Oxygen Analyzer Manual “Watchdog” AMI, Costa Mesa, CA...

  • Page 2: Table Of Contents

    Contents Preface Thank you! Caution Address Watchdog Oxygen Analyzer Introduction Features: Oxygen sensor: Sensor Warranty: Instrument Warranty: Installation and Operation Receiving the analyzer Installation. -------------------------Points to consider first! ------------------------------ Location: Safety Considerations: Flashing Display:...
  • Page 3 Power connections: Output connections: Sample Handling: Gas pressures: Sensor Installation: Hydrogen Sulfide: Communications Advanced Features Maintenance and troubleshooting Maintenance: Periodic Calibration: Sensor Replacement: Shorting clip: Sensor replacement cautions: Sensor replacement procedure: Bleeding a regulator Troubleshooting  2 AMI Analyzer Manual...
  • Page 4 Basics of trace oxygen troubleshooting Specifications and Disclaimer Specifications: Disclaimer  3 AMI Analyzer Manual...

  • Page 5: Preface

    Please verify that the analyzer was not damaged in transit. If so please contact the shipper as well as AMI. Trace Oxygen measurement is difficult because the air contains high levels (209,000ppm) of oxygen, and it will get into the smallest leaks.

  • Page 6: Introduction

    Watchdog Oxygen Analyzer Introduction The Watchdog provides the essential elements of a complete oxygen analyzer, but omits features that are duplicated by the flow computers with which it is intended to be used. If provides a complete sample control system, a means of calibration and a user-configurable analog and digital output.

  • Page 7: Oxygen Sensor

    The sensor is warranted to operate for a period determined by its class. If the sensor ceases to operate correctly before this time has elapsed, contact AMI for a return authorization for evaluation. If there is any evidence of defective material or workmanship the sensor will be replaced free of charge.

  • Page 8: Watchdog Oxygen Analyzer

    Sample conditions – if your sample is hot and wet, you will need to keep water from condensing in the sample line or analyzer. The AMI demister brings hot and wet gases back to ambient temperature and allows the condensation and entrained liquids to fall back into the pipeline (no draining is necessary, unlike a coalescing filter which requires routine maintenance).

  • Page 9: Location

    Class 1 Division 1 area, or inside another sealed box. Flashing Display: A flashing display indicates that the unit is measuring percent ranges. When the unit is measuring ppm levels of oxygen its display will be steady. Installation and Operation  6 AMI Analyzer Manual...

  • Page 10: Short-Form Installation Procedure

    Short-form Installation Procedure Figure 1. The Watchdog 1. Mount analyzer at a convenient eye level, not too close to the right wall. 2. Connect the analyzer ground to an 8 ft. ground rod or similar high quality ground with a minimum 16AWG wire.

  • Page 11: Laptop Set Up Procedure

    1. Make sure the laptop has the FTDI driver installed. a. Windows 7 will probably find the driver by itself, but XP probably won’t. b. Run the program called CDM20824_Setup.exe which is either in the AMI CD, or can be downloaded from the FTDIchips.com site.
  • Page 12 8. If you want to name the analyzer, click on the “User ID:” box. A dialog box will come up, asking for a password. Use “AMI” as the password, and then write in up to 12 characters as a name for the analyzer.

  • Page 13: Expanded Installation Procedure

    Expanded Installation Procedure Figure 2. The Watchdog This section follows the format of the installation procedure above but with greatly expanded explanations and coverage of detail issues. 1. Mount analyzer in a shelter if possible, at a convenient eye level, not too close to the right wall.
  • Page 14 Compressors heat the gas and also cause liquids to condense, particularly when the gas cools off, so that even apparently dry gas going into a compressor may contain liquids coming out. AMI can provide a “Demister” and Liquid Rejection Probe” that together work to prevent problems from hot wet gases.
  • Page 15 The Flow Control Valve is the metering valve in the middle of the Sample/Span/Off valve. It is a sensitive needle valve – so don’t try to use it to shut off the flow. Turn the main valve to the OFF position for this. Expanded Installation Procedure  12 AMI Analyzer Manual...
  • Page 16 You don’t push out one gas with another – the new gas simply dilutes the old gas in the system. Again, this is not intuitively obvious. Expanded Installation Procedure  13 AMI Analyzer Manual...
  • Page 17 “-“ connection at the analyzer. The terminal marked by the ground symbol may be used for this purpose, in which case the output is no longer isolated. DO NOT GROUND Expanded Installation Procedure  14 AMI Analyzer Manual...
  • Page 18 Do this before you screw on the cell cap, because you will get rid of most of the air in the cell pocket immediately, helping the sensor come down quickly. 19. Purge with sample gas for half an hour, or until the oxygen reading has fallen to low ppm levels Expanded Installation Procedure  15 AMI Analyzer Manual...
  • Page 19 20 seconds before you tighten it. It is preferable to use the AMI special flexible non-diffusive tubing with its O-ring sealed fittings so that you don’t destroy the span inlet fitting on the analyzer. This can be purchased from AMI as an option.
  • Page 20 Rotate the valve back to the Sample position. The analyzer is now set up and calibrated. It is normally good practice to give it a day or two and recheck the calibration. Expanded Installation Procedure  17 AMI Analyzer Manual...

  • Page 21: Analyzer Description

    Basic description: Figure 4. Analyzer (closed) The Watchdog measures oxygen in a flammable (or inert) gas stream down to under 0.1ppm. It is intended for use in non-hazardous or Class 1 Division 2 areas when properly installed. All components are contained in one compact enclosure. The sample system components are all integrated into a “Cell Block”...
  • Page 22 Figure 5. Outline Drawing Analyzer Description  19 AMI Analyzer Manual...

  • Page 23: General Information

    As a consequence of this, the integrity of the oxygen analyzer sample system is critical. AMI analyzers are designed around a patented “Cell block” that integrates all of the sample handling elements into one solid chunk of metal, resulting in much fewer leak sources and therefore much greater reliability, as well as lower cost.

  • Page 24: Sample Tubing And Components

    O rings. The span gas pressure should also be held below 100psig, and normally would be controlled to 10psig. AMI recommends that you use a length of their flexible tubing with O ring seals on its fittings so that you don’t damage the analyzer fittings by making and breaking them too often.
  • Page 25 Connect the regulator to the analyzer with a flexible line such as that provided by AMI, and leak check the connection with “Snoop™” or similar leak detection fluid. Purge the line for several minutes with a small flow of gas prior to doing this, and leave the gas flowing while you make the connection to the analyzer.

  • Page 26: Gas Connections

    The exhaust must be arranged in such a way that it will not plug under any circumstances. A typical means of ensuring this is to run the exhaust line next to the (warm) gas lines so that it always remains above Analyzer Description  23 AMI Analyzer Manual...

  • Page 27: Power Connections

    This unit is provided with a single output, either 4-20mA or 1-5V as ordered. It is possible to change this and also to calibrate the output to the monitoring device using the AMI User Interface. See the AMI User Interface manual for details on this.

  • Page 28: Sample Handling

    NOTE: Never allow the vent to become restricted, thus back-pressuring the sensor. Doing so will cause inaccurate readings and may damage the sensor Analyzer Description  25 AMI Analyzer Manual...

  • Page 29: Gas Pressures

    Communications The Watchdog supports both a USB link to a local PC, and RS485 over a network. Only one of these can be active at a time, and the unit automatically turns off the RS485 if it detects a computer plugged into the USB connection.

  • Page 30: Maintenance And Troubleshooting

    Maintenance and troubleshooting Maintenance: The Watchdog is virtually maintenance free other than for periodic calibration and occasional sensor replacement. Periodic Calibration: The analyzer should be calibrated about once every month to obtain the best accuracy. The sensor typically declines in sensitivity by about 1% per month, so a monthly calibration is usually satisfactory. Use in a particularly aggressive environment may degrade the sensor faster: in this case calibrate more often.

  • Page 31: Sensor Replacement Cautions

    9. Replace the cell cap. 10. Screw it down tightly but only hand-tight. 11. Dispose of the old sensor in an environmentally appropriate way. It is similar to a lead-acid battery in terms of environmental hazard. Maintenance and troubleshooting  28 AMI Analyzer Manual...

  • Page 32: Bleeding A Regulator

    14. Now open the bottle valve, and the shut off valve, and allow gas to flow through the tubing to the analyzer for two minutes before tightening the compression fitting on the analyzer.. Maintenance and troubleshooting  29 AMI Analyzer Manual...

  • Page 33: Troubleshooting

    The sensor and analyzer are in fact very linear, so if the analyzer now says that the span gas has a lot more oxygen than the label on the tank states, Maintenance and troubleshooting  30 AMI Analyzer Manual...
  • Page 34 6. Water may have shorted out the contacts on the back of the sensor. If so, use a Liquid Rejection Probe with a cooling coil or coalescing filter to make sure that condensation does not occur within the analyzer. Maintenance and troubleshooting  31 AMI Analyzer Manual...
  • Page 35 If not, the contacts may be bent. If they have been bent too much, remove the sensor and gently bend them back so that they can again make contact. Maintenance and troubleshooting  32 AMI Analyzer Manual...
  • Page 36 2. Verify that the span gas bottle is correctly marked by comparing its reading when the analyzer has been spanned on air to what it actually says. Still no correct operation 1. Call AMI at 714 848 5533, and ask for Technical assistance. 2. Or contact us by email at sales@AMIO2.com. Maintenance and troubleshooting  33...

  • Page 37: Specifications And Disclaimer

    Viton O-rings  Unaffected by changes in flow rate from 0.1 to 2.0 SCFH  Wall mount or 2.0” pipe Mounting:  7.0”W x 6.5”H x 4.5”D Dimensions:  Weight: 6 lbs. Specifications and Disclaimer  34 AMI Analyzer Manual...

  • Page 38: Disclaimer

    AMI’s obligation is expressly limited to the analyzer itself. The AMI analyzer is not designed as a primary safety device, that is to say it is not to be used as the primary means of assuring personnel safety. In particular it is not designed to act as a medical instrument, monitoring breathing air for correct oxygen concentration, and should not be used as such when it is the only safety device on the gas system.

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