Columbus Instruments 180 C Instruction Manual

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Model 180 C

Instruction Manual

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Page 3: Table Of Contents
4 System Diagnostics ........................... 51 5 Calibration ........................... 53 6 Experiment ........................... 62 7 Data file format ........................... 66 Part III Quick Reference 1 System Setup Hints ........................... 67 2 Running an Experiment ........................... 67 Index © <1985-2013> ... Columbus Instruments International...
Page 4: Part I Hardware
Hardware Introduction The 180 C Gas Analyzer is a multi channel gas sampler that is capable of measuring up to 6 gases in up to 80 different gas streams (channels) The system consists of a System Sample Pump, Expansion Interface and an individual gas sensor for each gas that is measured. The...
Page 5 Electrochemical Fuel Cells consume some of the target gas during the measurement. Therefore, the amount consumed is taken into consideration when making calculations and subsequent measurements. © <1985-2013> ... Columbus Instruments International...
Page 6 Model 180 C gas analyzer Non-Dispersive Infrared Detection: This method of measurement is made by simple spectroscopy; emitting a known amount of a specific wavelength of infra-red light through a sample and recording the amount absorbed by the sample. We use this method for the detection of Carbon Dioxide, Methane, and Carbon Monoxide (10%).
Page 7: Specifications
It is highly recommended to use an AC power filter/surge suppresser with the system to protect all instrumentation. The 180 C system warranty does not cover damage due to power surges. It is also a good idea to connect the system (including the computer) to an un- interruptable power supply.
Page 8 Model 180 C gas analyzer To make a connection using the nut and ferrule, slide the nut onto the end of the tubing and then slide on the two-part ferrule. Allow 0.25 cm of tubing to stick out beyond the end of the ferrule.
Page 9 "Sensor Out" fitting to the "Sensor In" fitting on the additional sensor. Finally, the long piece of tubing is used to connect the "Sensor In" fitting of the Carbon Dioxide sensor and the "Sensor Out" fitting of © <1985-2013> ... Columbus Instruments International...
Page 11 Hardware Sample drier connections All systems are equipped with a sample drier the sample drier removes the water vapor for accurate analysis. Connect as shown with the 1/8" tubing © <1985-2013> ... Columbus Instruments International...
Page 12 Model 180 C gas analyzer Connect the drying column(S) to the sample drier Connection of toxic gas sensors Some systems are equipped with what are referred to as toxic gas sensors. The H2, H2S, CO, NO2, SO2, NO, NO2 sensors are all toxic gas sensors. They have the special requirement that the sample gas cannot be completely dry.
Page 13 Hardware Then connect any additional toxic gas sensors in series if the system is equipped with more than one © <1985-2013> ... Columbus Instruments International...
Page 14 Model 180 C gas analyzer Then connect the sensor out fitting (of the last sensor for systems with more than 1 toxic gas sensors) © <1985-2013> ... Columbus Instruments International...
Page 15 If the system does not include an Expansion Interface, connect the sampling line to the System Sample Pump. Be sure to use a filter to protect the sample pump from contamination. © <1985-2013> ... Columbus Instruments International...
Page 16 Model 180 C gas analyzer If the system includes an Expansion Interface, connected it to the System Sample Pump using a single piece of tubing © <1985-2013> ... Columbus Instruments International...
Page 17 If the system includes more than one Expansion Interface, a small manifold, "T" fitting, or union cross fitting will also be included. Connect the manifold to the system sample pump as shown in the drawing below: © <1985-2013> ... Columbus Instruments International...
Page 18 Model 180 C gas analyzer Cable Connections Pictures below depict the proper cable configuration. To connect the cables, find the 25 conductor cables with the two female ends. If the system is configured with two sensors then there should be a total of three 25-pin cables. If the system is equipped with additional sensors then there should be an additional cable per sensor.
Page 19 Hardware Each additional sensor connects in series with the 25 pin cables © <1985-2013> ... Columbus Instruments International...
Page 20 If this is the case a 9 to 25 pin adapter will be needed. This adapter can be purchased at any local computer store or it can be obtained from Columbus Instruments. Use the remaining 25 pin cables with male connectors to connect the expansion units to the system sample pump.
Page 22 Model 180 C gas analyzer Connect the temperature probe to the "TEMPERATURE PROBE" input on the rear of the System Sample Pump. A second temperature probe, labeled "Expansion", is included with the Expansion Interface and inserts in the "Temperature Probe" connector located on the back panel of the first Expansion Interface.
Page 23 If the system includes a condensing air drier connect as shown in the picture above. The glass bottle is used to collect the condensed water from the sample stream and must be emptied periodically. © <1985-2013> ... Columbus Instruments International...
Page 24 Model 180 C gas analyzer Hardware Controls System Sample Pump The System Sample Pump has a flow control valve on the sample flow meter on the right side of the front panel. The flow meter on the left shows the flow rate of the sample stream of air through the sensors.
Page 25 0.50 L/min (500 cc/min). The following is a list of the connections and hardware controls on the rear panel of the System Sample Pump. The numbers corresponds with the labels in the following diagram. © <1985-2013> ... Columbus Instruments International...
Page 27 Gas Sensors The 180 C can be configured to monitor up to three different gas sensors. Each sensor is preset at the factory to operate with one another. If more than three sensors were purchased there is a chance that two or more sensors are configured to operate at the same Analog address.
Page 28 Model 180 C gas analyzer 1. POWER LED. Indicates power is on. 2. OFFSET DIAL. Used to adjust the offset or zero point of the sensor during the calibration procedure. 3. GAIN DIAL. Used to adjust the gain or span of the sensor during the calibration procedure.
Page 29 Whenever the range of operation is changed, the sensor must be recalibrated and the software reconfigured for the correct range of operation. The following is a list of controls and connectors corresponding to the following diagrams. © <1985-2013> ... Columbus Instruments International...
Page 30 Model 180 C gas analyzer 1. POWER LED. Indicates power is on. 2. COARSE GAIN DIAL. Used to adjust the gain set-point of the O2 sensor during the calibration procedure. 3. FINE GAIN DIAL. Used to fine-tune the gain or span of the O2 sensor during the calibration procedure.
Page 31 3. FINE OFFSET DIAL. Used to fine-tune the offset set point of the O2 sensor during the calibration procedure. 4. SPAN DIAL. Used to adjust the span or gain of the O2 sensor during the calibration procedure. © <1985-2013> ... Columbus Instruments International...
Page 32 Model 180 C gas analyzer 1. SENSOR IN FITTING. Connects to the "Sensor Out" connector on the CO2 sensor, or to the "Sensor Out" connector on the System Sample Pump for O2 only systems. 2. SENSOR OUT FITTING. Connects to the "Sensor In" connector on the System Sample Pump.
Page 33 90% of the full range would be required. (actually ambient air can be used, it contains 20.93% O2) This example will have a higher sensitivity of measurement because of the smaller range of measurement © <1985-2013> ... Columbus Instruments International...
Page 34 Model 180 C gas analyzer CO / H2S / SO2 / H2 Sensors These sensors are electro-chemical based and require a two-point gas calibration procedure. The first step is to offset the sensor, which is done with gas free of the specific gas the sensor is designed to measure.
Page 35 2. OFFSET DIAL. Used to adjust the offset or zero point of the sensor during the calibration procedure. 3. GAIN DIAL. Used to adjust the gain or span of the sensor during the calibration procedure. Toxic Gas Sensor Controls © <1985-2013> ... Columbus Instruments International...
Page 36 Model 180 C gas analyzer 1. SENSOR IN FITTING. Connects to the Sensor Out connector on the previous sensor. 2. SENSOR OUT FITTING. Connects to the Sensor In connector on the next sensor (if equipped) or to the Sensor In connector of the System Sample Pump.
Page 37 3. GAS SAMPLE IN FITTING. This is where the gas from sample chamber (flask) enters the system. Always connect a 0.2 micro PFTE filter to this connector as shown in the picture to protect the instrument. 3. GAS SAMPLE FILTER. 0.2 micro PFTE filter © <1985-2013> ... Columbus Instruments International...
Page 38 Model 180 C gas analyzer Expansion Unit Rear Connections 1. OUT FITTING. This is connected to the "Test In" fitting on the Sample Pump. 2. FUSE HOLDER. Replace with 3 amp fuse only. 3. . POWER CONNECTOR. This connects to the power mains. The power switch is also located here.
Page 39: Operations
For increased protection against liquid entering the system, PFTE hydrophobic membrane filters should be placed in the gas sampling line going to each chamber. The picture below shows the connection for these filters. These filters are available from Columbus Instruments. An additional...
Page 40 Model 180 C gas analyzer * NOTE: This circuit detects liquid by measuring conductance, it will not work with distilled water. Air Flow-Rate Settings The sample flow should be set to 0.5 l/min. The sample flow is adjusted using the metering valve on the "Sample Flow"...
Page 41: Maintenance
Maintenance Replacement of the Oxygen Sensor The 180 C oxygen sensor is designed to supply about nine months of service. Replacement of the sensor is indicated when the desired calibration Set-point oxygen level can no longer be obtained (ie increasing the gain during calibration has no effect). The drawing on the following page shows the oxygen sensor housing assembly.
Page 42 Model 180 C gas analyzer 4. Slide the sensor assembly out 5. Verify the red o-ring is on the top nipple of the sensor as shown in the picture below. 6. Slide the assembly back into the housing. © <1985-2013> ... Columbus Instruments International...
Page 43 80% pink it should be changed. When there are 2 drying columns attached to the sample drier, one can be removed and the remaining one will still dry the sample gas © <1985-2013> ... Columbus Instruments International...
Page 44 Model 180 C gas analyzer and not disturb the experiment. Replace the chemical with new and re-connect it. The chemical can simply be replaced or it can be recharged by placing in a thin layer and backing at 200 C for a few hours until it changed back to blue ©...
Page 45: Part Ii Software
180 C Icon located in the Programs Menu. Running Software The 180 C software can be run clicking on the 180 C folder located in the Programs Menu. The first time the software is run, the software will prompt the user to insert the 3.5" System Configuration Disk to update the software's configuration file.
Page 46: Main Menus
As the software loads the system will automatically search the computers communication ports for the 180 C hardware. If the hardware is not found then the user will be notified that the Device is not connected. The program will need to be restarted to reestablish the connection with the hardware.
Page 47 The Experiment Menu is used to setup parameters for new experiments. A new experiment can also be started from this menu. Experiments that have been run previously can also be opened and viewed from this menu. © <1985-2013> ... Columbus Instruments International...
Page 48 Model 180 C gas analyzer Tools Menu The Tools menu contains utilities to measure chamber leakage, volumes ad restrictions. Extensive System Diagnostics used to test each component of the system can be run from this menu. Sensor calibration can be performed from this menu as well.
Page 49 Software Window Menu This menu allows the user to arrange various active windows in a cascade, tile Horizontal or Tile Vertical. A list of active windows are also listed in this menu. © <1985-2013> ... Columbus Instruments International...
Page 50: System Properties
System Properties The system properties contain variables that are specific to the 180 C hardware. Most of these settings are configured at the factory and can not be changed. Some values that pertain to calibration settings and volume settings can be set by the end user.
Page 51 Sensors Tab. The sensors tab contains information used to configure the sensor present with the system. The 180 C windows software can support up to 6 sensors. Sensor Type. Sensor type select what type of sensor is installed in the system. This setting is configured at the factory when the instrument is purchased.
Page 52 Model 180 C gas analyzer instrument. This setting is factory set and can not be changed by the customer. System Timing. These values are used to set the amount of time the system circulates gases during purging, settling and purging of the system. These values are factory set and can not be changed.
Page 53: System Diagnostics
Each test is followed by a standard deviation and a PASS/FAIL statement. Once the Test has finished the user will be prompted to save the results to the system log which can be later sent to Columbus Instruments for analysis. Valves and Sensors The Valves and Sensor Diagnostics tests the sensors, restriction , leakage and volumes.
Page 54 Model 180 C gas analyzer Expansion Unit The Expansion Unit Diagnostic tests integrity of each chambers connection to the expansion unit. Each chambers restriction, leakage and volume is measured to ensure proper operation. By replacing the chamber with a short piece of tubing the operation of the expansion unit can be tested.
Page 55: Calibration
Columbus Instruments for technical assistance in troubleshooting problems. Calibration The Model 180 C requires periodic calibration of the gas sensors and mass flow meters (if enabled) to insure precise measurements. The calibration procedure consists of the application of a gas of known composition and adjusting controls on the front of the Oxygen, Carbon Dioxide and any other gas sensors to obtain readings that reflect the contents of the calibration gas.
Page 56 Model 180 C gas analyzer Calibration Gas Specifications The recommended calibration gas is termed "Primary Standard" by suppliers and is usually the most precise mixture available. The cylinder of gas must be ordered from a local gas supplier. The supplier will include a...
Page 57 H2 sensor and a 200 ppm H2S sensor. Lets say that the gas was supplied in 3 cylinders one containing 4.5% CO2 + 0.9 CH4, one containing 1800 ppm H2 and a third containing 180 ppm H2S. Below would be the correct configuration: © <1985-2013> ... Columbus Instruments International...
Page 58 Model 180 C gas analyzer See the picture below for the connection of the span gas(s) cylinder(s) © <1985-2013> ... Columbus Instruments International...
Page 59 "Nitrogen" The purpose of the soda lime column is to remove the atmospheric CO2 to provide a "zero" gas to the set the zero (offset) of the CO2 sensor. The connection is shown below: The soda lime column can remain connected all the time. © <1985-2013> ... Columbus Instruments International...
Page 60 Model 180 C gas analyzer Please note that if the paramagnetic oxygen sensor is used in the range where the offset if 0, a bottle of nitrogen must be connected to the nitrogen port with a "T" fitting in the same was as the calibration gas cylinder.
Page 61 0.5 l/min. At this point adjust the knob on the sample flow meter for a reading of 0.5 l/min Then click OK Then a timer will countdown to zero and during this time the gas is just allowed to circulate through the sensors. © <1985-2013> ... Columbus Instruments International...
Page 62 Model 180 C gas analyzer After the timer reaches zero, then the user will be prompted to adjust the zero knob on each sensor for a reading of 0 on the screen. The numbers will turn blue to indicate which sensor(s) should be adjusted at this point.
Page 63 Press next gas and repeat the previous 2 step again for each cylinder (gas bottle) until all gas sensors have been calibrated. After the last cylinder the software will prompt you to turn off the calibration gas bottle. Calibration is now complete © <1985-2013> ... Columbus Instruments International...
Page 64: Experiment
Model 180 C gas analyzer Experiment The Experiment Menu enables the user to setup a new experiment to be run, and view previously run experiments. Only one experiment can be run with the current version of windows. Three previously ran experiment can be viewed at once.
Page 65 Experiment data can be viewed while the experiment is running or after that data has been collected. The Data is presented in both statistical and graphical forms. In the statistical data window the data is scrolled down the screen as the experiment progress. There are scroll bars © <1985-2013> ... Columbus Instruments International...
Page 66 Model 180 C gas analyzer located on the right of the data grid allowing the user to scroll through the data. If the data is viewed while an experiment is running the Experiment Status Window will be present. Data The data tab displays the data collected since the beginning of the experiment.
Page 67 The data can be graphed while the experiment data is collected, or while viewing an older experiment. A total of 10 chambers can be viewed at one time in this section. Also the type of data graphed can be selected to be graphed. © <1985-2013> ... Columbus Instruments International...
Page 68: Data File Format
Model 180 C gas analyzer Channel Selection. When graphing experiment data total of ten chambers can be display at one time. If an experiment contains more than ten chamber any chamber can be displayed at one time, however the total chamber displayed at one time is limited to ten. A Zero line can be displayed to show the zero line on the graph.
Page 69: Part Iii Quick Reference
System Setup Hints Power Requirements The 180 C System requires a very stable AC power source. Fluctuations in the AC line voltage or frequency can be reflected in the data collected. It is recommended that the System not be powered by an AC circuit that also supplies power to devices that require a large amount of power to operate.
Page 70 The dryers connected to the sample drier should be checked and refilled if needed. System Diagnostic Ran The 180 C contains diagnostic procedures that will check the function of each section of the instrument for proper operation. The system Diagnostics include the Basic Operations, Valves and Sensor, and the Expansion Unit Diagnostics.
Page 71 Back Cover...

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