Operating Manual. Gas chromatograph GC 5000 BTX

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1 Operating Manual Gas chromatograph GC 5000 BTX

2 Address of manufacturer: AMA Instruments GmbH Soeflinger Straße Ulm, Germany Tel Fax Imprint: Operating Manual GC 5000 BTX Version 5.0; English Date: 11/2010

3 Table of Contents Page 1.0 Information for the owner How to use the manual Specific normal operation Delivery information Standard and regulations Declaration of conformity Copyright Service address Hazard Information General hazard information Responsibility of the operator Product description - technical specifications Normal use of GC 5000 BTX Hardware description Description of GC components System control and watchdog GC oven Columns Detector Setup of parameters Technical data (GC 5000 BTX) Options Calibration gas selector (optional) Ozone precursor monitoring system (optional) Optional modules Dilution module DIM Sample stream selector SSM Installation Safety instructions Installation condition Gas connections Electrical connections Start up and shut down Safety instructions Start up instructions Decommissioning Setting up the GC 5000 Software Status screen How to unlock password protection How to select operation modes How to select master modes How to select communication parameters Analog outputs configuration Alarm configuration Gesytec specifications Modifying parameters under Gesytec specifications Operating Manual GC 5000 BTX; Version 5 11/2010 1

4 7.0 Starting operation How to start measurement How to adjust the retention time windows How to zoom / zoom out the chromatogram How to optimize integration parameters Using LCD display and buttons on the front panel Calibrating and validating Calibration Calibration intervals How to enter the data of calibration gas concentrations Enter data - without a calibration gas module How to disable concentration levels Enter data - with a calibration gas module How to start a calibration Calibration of one level Calibration of sequence (without calibration module or cal. valves) Auto-calibration Validation Principle of validation Types of validation How to start validation Functional description Measuring principle Definition of the program step Program example Software reference Basic software design Software architecture Configuration files Main window: Program Menu items Unlock Parameters Change password Operation mode Remote control Master mode Method Analysis GC Oven Calibration Validation set up 84 Page Operating Manual GC 5000 BTX; Version 5 11/2010 2

5 11.0 Software reference continuing Page Analog output configuration Alarm configuration CP Analysis CP File Editor Module setup Program steps Standard BTX BTX with stripper Column View Run calibration (manual and auto-calibration) Run validation Help functions Remote support About (current Software Version) Miscellaneous procedures Programming and editing values Programming GC oven parameters How to display the running temperature program Select the parameters for the running temperature program Start and stop Subsequent data processing Maintenance Security instructions Maintenance schedule Maintenance work Exchange the enrichment tube Maintenance of the pump Exchange the input filter of the MFC Exchange or repair the capillary column Adjust the detector signal Check the glow plug Check the thermocouples Check the heating units of detector and valve oven Exchange of the PID lamp Clean the PID lamp window Exchange the rotor of the rotary valve Exchange the GC oven motor Exchange the back panel fan Exchange the Peltier cooler fan FID maintenance Troubleshooting General faults Alarm messages Warning messages Error messages Spare parts list. 140 Operating Manual GC 5000 BTX; Version 5 11/2010 3

6 16.0 Warranty GESYTEC-II protocol Telegram definitions Status request MZ Status response ZM Data request DA Data response AD Control command ST Control response TS Appendix Page 18.0 Digital I/O General Digital outputs Digital inputs Operating Manual GC 5000 BTX; Version 5 11/2010 4

7 1 Information for the owner 1.1 How to use the manual Caution! Please read this manual carefully before starting with operation. The manual will provide you with information on using, installing, operating and maintaining this unit. It ensures proper functioning and helps you to operate the device more easily and efficiently. Symbols: Caution! Pay particular attention to all kind of warnings and notes. Information of this type is set apart from the rest of the text and specially identified by appropriate symbols and pictograms 1.2 Specified normal operation Before the system left the factory, it has been inspected and found to be in perfect condition as regards safety. To ensure a safe and problem-free operation, the product should only be used in the manner described by the manufacturer. In addition, proper transportation, storage and initial installation are vital to ensure a correct and safe operation as well. This manual provides the information you will need to use the described product in the proper manner for which it is intended. This manual includes several safety information (including warnings). The knowledge of this information is essential for hazard-free installation and operation as well as maintenance. Therefore the manual refers to technically qualified personnel especially trained and authorized for maintenance and service of analyzer and monitoring devices. Moreover they possess the knowledge of correct interpretation of the safety information and warnings provided in this manual. This ensures as well to put it properly into practice. Note The GC 5000 is configured and calibrated ex factory with your required application. In particular you intend to use the analyzer for new applications, we recommend you to contact your local supplier to discuss the application in question. (See chapter 2.2 and 3.1as well) Operating Manual GC 5000 BTX; Version 5 11/2010 5

8 1.3 Delivery information When you receive the shipment, please check the following: 1. The packaging is not damaged. 2. Both indicators labels which are fixed on the package should display the white color as a sign for proper transportation. The package of the analyzer is posted with one so-called shockwatch indicator label and one tilt watch indicator label. Both labels change their color from white to red in case of improper handling by the forwarder regarding tilts and shocks. Note! In case one of the indicator labels is red or both, note it on bill of lading, inspect the shipment for damage and inform AMA Instruments within 10 days after arrival at latest. The scope of delivery is corresponding to the relevant purchase contract and is shown on the documents enclosed with the shipment: 3. Open the packaging and check whether the shipment is complete. 4. Check the serial number on the type plate with the serial number specified in the shipping documents. 5. The operating manual is delivered on CD-ROM and recorded on the PC of the analyzer as well. Note! Do not throw the original packaging away: A saver shipment is guaranteed while using the original purpose-made packaging (it contains foamed plastic inserts which are adapted to the size of the analyzer). Therefore we recommend the storage of the original packaging. 6. First visual check-up of the analyzer: When unpacking the system, remove the cover and have a closer look to the interior of the analyzer. The following checklist may be of help: All parts are fixed Check additionally if the plug in card and the riser card are fixed properly (optional installation) Remove the cover of the GC oven and make a sight check of the column In case the column is broken, follow the instruction of chapter how to cut and repair a capillary column in the right way. Operating Manual GC 5000 BTX; Version 5 11/2010 6

9 1.4 Standards and regulations As far as possible the specifications and manufacture of this unit are based on the harmonized European standards. If this product is used outside the area of validity of these standards and regulations, the standards and regulations valid in the owner s country should be observed. 1.5 Declaration of conformity Our product GC 5000 BTX is manufactured in compliance with the following standard(s) or documents: Low-Voltage Equipment Directive 2006/95/EG EMC Directive 2004/108/EG Harmonized standards EN and EN In accordance with the named above EC directives, the EC Declarations of Conformity are kept available for the relevant Authorities by AMA Instruments GmbH Soeflinger Strasse 100 D Ulm / Germany If this product is used outside the European Union, the standards and regulations valid in the owner s country must be observed. Operating Manual GC 5000 BTX; Version 5 11/2010 7

10 1.6 Copyright The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Technical data are subject to change. All rights are reserved by AMA Instruments GmbH, Ulm, Germany. 1.7 Service address If you require further information, which are not treated in sufficient depth in this document or in case of malfunction, please contact your local supplier. The responsible service engineer will provide you with the required information. In case of malfunction, it is recommended to have the following information on hand: Detailed description of the failure Serial number of the system (on the back side of the analyzer) Note! In case of a repair, we would welcome your detailed information about the failure in order to assure an efficient handling for a fast return shipment of your system. Note For a saver shipment we recommend the use of the original packaging of the analyzer which is purpose-made. (It contains foamed plastic inserts which are adapted to the size of the analyzer.). For proper shipment the system should be transported on a pallet. Operating Manual GC 5000 BTX; Version 5 11/2010 8

11 2 Hazard information 2.1 General hazard information Please observe the following notes to safeguard against damage to the system described as well as to any systems which may be connected to it. Safety information and warnings are given particular emphasis in this manual by means of various symbol terms defined below. They apply to both, users and service / electrical technicians. They intend to help preventing dangers to life and health as well as preventing damages to properties. These notes are also marked by warning symbols which reflect the meaning of the accompanying text. Within the context of this manual and information on the product itself, the terms used are defined as follows: Danger! This means that death or severe injury or considerable damage to property will result if the corresponding precautions are not taken. Warning! This means that death or severe injury or considerable damage to property could occur if the corresponding precautions are not taken. Caution! This means that damages to property may result if the corresponding precautions are not taken. Note Provides important information about the product, about using it or about a corresponding part of the manual to which special attention has to be shown. Operating Manual GC 5000 BTX; Version 5 11/2010 9

12 2.2 Responsibility of the operator The analyzer described can only be used for applications which are described in chapter 3.1. For operation of the system, the technical data described in chapter 3.4 must be observed. The analyzer described in this manual has been designed, manufactured, inspected and documented in compliance with the relevant safety standards. The design of the GC 5000 BTX ensures a safe operation. If the operator follows the handling requirements and observes safety instructions which are described for installation, operation and maintenance, then the system will be not a source of danger to individual health and safety or to property. Warning! In case you open the unit, certain parts which apply hazardous voltage become accessible. Only qualified and accredited technicians in the field of electricity are permitted to have access. Only qualified and trained personnel with a thorough knowledge of all sources of danger are permitted to have access to this system. Regarding the safety information in this manual, qualified personnel is defined as follows: The operating personnel They are trained in operating the system and observing its safety requirements. As well they are familiar with the operation-related content of this manual. This means they are able to fully understand the English written safety instructions. The commissioning or maintenance personnel They are authorized to install, operate, maintain and repair this kind of systems and electrical circuits in accordance with accepted technical safety standards. They possess the authorization and appropriate training to putting into operation, maintain and repair this system. Furthermore they are able to fully understand the English written safety instructions and maintenance requirements as well. Operating Manual GC 5000 BTX; Version 5 11/

13 3 Product description - technical specifications 3.1 Normal use of GC 5000 BTX The AMA GC 5000 BTX has been developed for the continuous monitoring of emission and immission levels of organic compounds in ambient air and gas streams in the range of C 4 C 12. The instrument is characterized by its compact design and its outstanding detection sensitivity in the ppt- range. The analyzer is type approved according to DIN EN (August 2005) and can be used for the legally obliged monitoring of benzene in ambient air according to the guideline 2000/69/EC of the European parliament and the council from November 16th At the same time often concentrations of other aromatic hydrocarbons are monitored as well. According to the EU guideline 2002/3/EC from February 12th 2002, the VDI guideline 2100 and the guidelines of the Technical Assistance Document EPA/600-R-98/161 of the American environmental protection agency EPA from September 30th 1998 the analysis system is also suitable for the continuous monitoring of ozone precursors in the range of C 4 -C 12. A system for continuous monitoring of the complete range of ozone precursor from C 2 -C 12 can be configured by combining the GC 5000 BTX and the GC 5000 VOC. General range of applications: Ambient air monitoring, immissions and emissions control Aromatic hydrocarbons (BTEX, styrene, trimethylbenzene, ethyltoluene) Aliphatic hydrocarbons (1,3-butadiene, methylcyclopentane, methylhexane) Chlorinated hydrocarbons (vinyl chloride, tri-chloroethene, tetrachloroethene) Application ex factory The GC 5000 BTX analyzer is configured and calibrated ex factory with your required standard application. This means that the equipment of the system is adapted specifically to the required measuring task. Operating Manual GC 5000 BTX; Version 5 11/

14 3.2 Hardware description - Overview The GC 5000 BTX analyzer is constructed as a 19 plug in case. All necessary parts are integrated as there are electronic control unit, PC, heater controller, gas regulation etc. and optional equipment as output requirements, calibration gas selector or controller for external devices as permeation modules etc. A 10 monitor is available optionally as well. Otherwise a monitor can be connected to the external VGA interface. Fig. 1: Front view of the GC 5000 Analyzer Operating Manual GC 5000 BTX; Version 5 11/

15 Fig. 2: Rear view Fig. 3: Gas regulation inside the analyzer Operating Manual GC 5000 BTX; Version 5 11/

16 3. 3 Description of GC components System control and watchdog System control is realized via a built-in PC board with Windows XP and the AMA control software. Note The GC 5000 features a hardware watchdog. In case of a software crash or an operating system crash, the watchdog resets the internal PC. Then the operating system and the AMA control software are started again automatically and the GC 5000 is operating properly again. The automated restart of the analyzer helps your service personnel: No extra visits to the monitoring station are necessary GC oven Columns Detector Setup of parameters The GC module features a three step temperature program. It enables to work with high end temperatures without having long cooling down-times as construction and used materials of the GC components are characterized by preventing from thermal inertia. The dimensions of the oven are 21cm * 21cm * 8cm which makes app cm 3. The geometry of the oven allows the use of columns with their own cages. The maximum linear heating rate for the range between C is 25 C/min, adjustable in steps of 1 C/min. The dimensions of the oven allow the use of commercial capillary columns. This helps to exchange a column in a few minutes. The GC can be equipped with capillary columns with an internal diameter of 0.32mm, 0.45mm or 0.53 mm and up to 60m length. For standard applications use a 0.32mm column. The standard detector is a FID (Flame Ionization Detector) or a PID (Photo Ionization Detector). The output of the detector is an analog signal of 0-5 V. The signal is digitized and analyzed by chromatography software. The control software allows to enter and to modify all analysis parameters. Unauthorized access is avoided due to password protection. Operating Manual GC 5000 BTX; Version 5 11/

17 3.4 Technical data GC 5000 BTX General Case Height Depth Weight Ambient temperature Humidity EMC 19 plug-in case 6 height units 600 mm approx. 40 kg 5 C to 35 C (if temp. exceeds this range, air conditioning is required) 5% to 95% relative humidity, non-condensing CE-marking, conformity with EMC guideline 2004/108/EG Instrument supply Voltage Line frequency Power consumption Carrier gas Supply gases (for FID only) Gas connections Pressure control Flow control VAC; VAC (optional) 50 to 60 Hz max. 800 W Nitrogen GC grade (5.0 = %), 3 bar Combustion air, GC grade 2 bar; H 2, GC grade, 2 bar 1/8 Swagelok Integrated pressure regulators, electronic readout of carrier gas pressure, manometers for indication of supply gas pressures (for FID only) MFC for precise flow control of hydrogen supply (for FID only) Sampling Sampling Volume measurement Sampling time Flow rate Sample volume Maintenance-free membrane pump for automated air sampling Mass flow controller with flow sensor for precise measurement and control of sample volume irrespective of fluctuations in atmospheric pressure and temperature 0-99 min (adjustable) MFC, 5-50 sccm/min (adjustable) Typical sccm (adjustable) MFC inlet filter Sintered metal filter, stainless steel 2µm Enrichment Enrichment module Enrichment temperature Desorption temperature Heating-up rate Single-stage enrichment module with integrated thermal desorption unit for pre-concentration of organic components C 4 Typical 30 C (adjustable) max. 350 C (adjustable) Up to 40 C/s providing high-speed sample introduction, which results in optimized peak separation Valve oven Oven liner Internal dimensions Heated valve block Sample valve Stainless steel H 70 mm x D 80 mm x W 210 mm Temperature controlled, adjustable from C 6-port VALCO valve, electrically actuated Operating Manual GC 5000 BTX; Version 5 11/

18 GC oven Oven liner Stainless steel Internal dimensions H 55 mm x W210 mm x D 210 mm Analytical column Fused silica capillary, length up to 60 m Heating Forced air Temperature range 40 C to 210 C Temperature control Closed loop PID, set point resolution 1 C Temperature program 3 linear heating ramps, 4 isothermal holds Heating rate 1 C/min to 25 C/min, set point resolution 1 C/min Oven cooling Fast cooling down due to forced air cooling Computer specifications Hardware Communication ports Protocols Operating system Protection Watchdog Intel Atom 1.6GHz dual core, 1 GB RAM, 2,5 hard disk 2x Ethernet, RS232 / RS 485, 4x USB, PS2, VGA GESYTEC II, other protocols on request Windows XP Professional Password protection Hardware watchdog for an automated restart of the analyzer in case of a software crash or an operating system crash. Detector (select one type) FID Flame Ionization Detector PID Photo Ionization Detector - Stable signal output due to temperature controlled detector block - Make-up gas connection provides enhanced detection sensitivity - Amplifier output 0-5 VDC - Requires H 2 and combustion air supply - Electrode-less, radio frequency excited UC lamp provides increased UV intensity and extended lifetime of lamp Options for GC 5000 Display 10 Touch screen Communication Various I/O modules, analog outputs and digital I/O Calibration Calibration gas selector (Sample, Cal1, Cal 2) Accessories Developed for optimized connection with GC 5000 Sample stream selector SSM 600, Art.-No Dilution module DIM 200, Art.-No Combustion air supply for FID Dry-running compressor with exchangeable charcoal filter; Art-No Operating Manual GC 5000 BTX; Version 5 11/

19 3.5 Options Calibration gas selector (optional) The AMA GC 5000 BTX can be equipped with two different calibration gas supplies. 1. Calibration gas generator: The analyzer is equipped with a communication interface to external gas generators. 2. Calibration gas cylinders: Fig. 4: Gas flow scheme of the calibration gas selector Optionally the analyzer can be equipped with a valve array for the selection of different sources of sampling. The array consists of 3 valves and can be used for one ambient source and two calibration sources. The needle valves of the calibration gas cylinders have to be adjusted to 70ml/min or more Ozone precursor monitoring system (optional) For the on-line monitoring of hydrocarbons C 2 -C 11 (ozone precursor) in one system, the AMA BTX analyzer can be synchronized with a AMA VOC analyzer. You have to select Master mode on in the BTX analyzer parameters and Slave mode on in the VOC analyzer parameters. Then each cycle and each calibration is started by the BTX analyzer. Operating Manual GC 5000 BTX; Version 5 11/

20 3.5.3 Optional Modules Dilution module DIM 200 Microprocessor controlled gas calibration Automated calibration of monitoring devices The DIM 200 provides calibration gas at specified concentration levels for precise calibration of monitoring devices. The calibration gas is generated by diluting a source calibration gas with zero gas (e.g. nitrogen or purified air). The DIM 200 can be controlled manually or remotely via bus communication by any AMA monitoring device or via digital I/O s. This allows for periodic validation and/or calibration of monitoring devices even while running in unattended operation mode. If the DIM 200 is controlled remotely by any AMA GC system, also setup of the module is fully integrated into the analyzer software. Technical data DIM 200: General Case Height Depth Weight Mounting Ambient temperature Humidity EMC 19 plug-in case 3 height units 400 mm 8 kg designed for cabinet / rack mounting 5 C to 40 C (if temp. exceeds this range, air conditioning is required) 5% to 95% relative humidity, non-condensing CE-marking, conformity with EMC guideline 2004/108/EG Instrument supply Voltage Line frequency Power consumption Supply gases Supply connections VAC 50 to 60 Hz max. 200 W Zero air (purified air or N 2) 3 bar; Source calibration gas, 3 bar Sample gas 1/8 Bulkhead union for calibration gas and sample in/out 1/4 bulkhead union for zero gas and bypass Gas flow control Source calibration gas Zero gas Dilution range 1 to 2500 Concentration levels Gas flow concentrations Supplied gases Mass flow controller, 2 to 100 sccm/min, accuracy +/- 0.5% of reading Mass flow controller, 100 to 5000 sccm/min, accuracy +/- 0.5% of reading Up to 5 levels (manual operation or remote control via digital I/O s) Up to 20 levels (remote control by AMA monitoring devices) Certification of the DIM 200 optionally available by factory-set correction of flow rates determined by an independent and accredited body for gas certification Digitally controlled solenoid valves to supply either sample gas, zero gas or calibration gas at sample out port Operating Manual GC 5000 BTX; Version 5 11/

21 Operation Module set-up Display Data entry Operation modes Menu-driven user interface for manual set-up and operation DIM 200 control software for convenient module set-up optionally available Large and back-lighted LCD display to indicate module status level, names of analytes, concentrations and dilution factors Splash-proof membrane keypad Manual operation, remote control via digital I/O s, remote control by any AMA monitoring device via bus communication Communication Communication ports Digital I/O s 2x RS-485, 25 pin SUB-D connector for digital I/O s Digital inputs for module control Digital outputs for indication of selected concentration levels, zero gas supply, sample gas supply, error status, equilibration mode and service mode Options Control software Certification DIM 200 control software for convenient module set-up Certification of DIM 200 (includes factory-set correction of flow rates) Order Number Dilution module DIM 200, Art.-No Sample stream selector SSM 600 The SSM 600 is a microprocessor controlled sample stream selector for monitoring of up to 6 gas streams. A menu-driven user interface allows for easy configuration of the SSM 600. The SSM 600 can be controlled manually or remotely. Remote control can be performed via digital I/O s by any external control unit or via bus communication by any AMA monitoring device. This allows for automated selection of sample streams while running in unattended operation mode. If the SSM 600 is controlled remotely by any AMA GC system, setup of the module is fully integrated into the analyzer software. All settings can be saved and loaded together with the analytical method. For effective purging of the sample line a low maintenance membrane pump is optionally available. Operating Manual GC 5000 BTX; Version 5 11/

22 Technical data SSM 600: General Case Height Depth Weight Mounting Ambient temperature Humidity EMC 19 plug-in case 3 height units 400 mm 8 kg designed for cabinet / rack mounting 5 C to 40 C (if temp. exceeds this range, air conditioning is required) 5% to 95% relative humidity, non-condensing CE-marking, conformity with EMC guideline 2004/108/EG Instrument supply Voltage Line frequency Power consumption Gas connections VAC without pump; VAC with pump ( VAC optional) 50 to 60 Hz max. 200 W 1/8 bulkhead union, stainless steel Operation Module set-up Display Data entry Operation modes No. of sample streams Menu-driven user interface for convenient configuration Large and back-lighted LCD display to indicate number of selected sample stream and module status Splash-proof membrane keypad Manual operation, remote control via digital I/O s, remote control by any AMA monitoring device via bus communication 1to 6 sample streams Communication Communication ports Digital I/O s 2x RS- 485, 25 pin SUB-D connector for digital I/O s Digital inputs for module control Digital outputs for indication of selected sample stream, error status, equilibration mode and service mode Options Low maintenance membrane pump for sample line purging (recommended for sample lines at a length of 5 meters or mores) Order Number Sample stream selector SSM 600, Art.-No Operating Manual GC 5000 BTX; Version 5 11/

23 4 Installation 4.1 Safety Instructions Warning! Electrical parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Therefore make sure that the housing of the GC 5000 BTX is closed before switching on. Caution! Hydrogen is combustible and explosive. Therefore avoid wrong gas connections. Disregard may result in damage to the system or cause malfunction and wrong detection results. All gas connections to the GC 5000 are labeled: Make sure that the supply of the gases (hydrogen, nitrogen, combustion air) is secured and the correct port for each gas line is used before switching on the system. Caution! Make sure that the correct gas pressures are used as described in this manual (see paragraph 4.3). Disregard may result in damage to the system. Therefore use the correct pressure values for the gases (hydrogen, nitrogen, combustion air) before switching on the system. Caution! Use nitrogen 5.0 (99,999%, GC-grade quality) as carrier gas and hydrogen 5.0 as combustion gas. Make sure that the combustion air is dry and free of oil traces. Pure gases prevent the system from contamination. Note During operation of the instrument the ambient temperature has to be at minimum 10 C below the starting temperature of the GC oven program in order to guarantee a reliable cooling down of the GC oven at the end of each cycle. Note! When using synthetic air with a very high purity instead of air from a zero air generator as combustion air, make sure that the FID signal offset of the FID amplifier is adjusted correctly (see chapter ). The FID signal may be lower with synthetic air than with zero air. If the signal is still < 100 mv when the flame is lit, you will get an alarm message (see chapter 14.2 alarm 5.3). Operating Manual GC 5000 BTX; Version 5 11/

24 Note Electrical connections are displayed on the type plate on the rear panel of the system. 4.2 Installation conditions An appropriate location for installation of the GC 5000 should be vibrationfree as far as possible. The system is suitable to run in measurement cabinets or containers. Make sure that the ambient temperature should be in a temperature range between 5 C and 35 C. Air conditioning has to be provided, if the temperature exceeds that range. Keep in mind that the analyzer produces waste heat, which has to be dissipated effectively. Note The ambient temperature during operation of the instrument has to be at minimum 10 C below the starting temperature of the GC oven program in order to guarantee a reliable cooling down of the GC oven at the end of each cycle. 4.3 Gas connections Fittings Bulkhead connectors for tube diameters of 1/8 (Swagelok) are provided to connect the gas lines to the GC The gas circuit diagrams as well as the type plate on the rear panel of the GC 5000 indicate the correct port for each gas line to be connected. Use 1/8 PFA hose or stainless steel tubing to connect the gas lines. Use functional, leak proof and clean tubing only to connect the required gases to the GC Gas pressures Pressure of combustion air: 2 bar (necessary for the FID flame). Pressure of the hydrogen: approx. 2 bar (necessary for the FID flame). Pressure of nitrogen: approx. 3 bar Caution! Hydrogen is combustible and explosive; avoid wrong gas connections. Disregard may result in damage to the system or cause malfunction and wrong detection results. All gas connections to the GC 5000 BTX are labeled. Make sure that the supply of the gases (hydrogen, nitrogen, combustion air) is secured and the correct port for each gas line is used before switching on the system. Caution! Use nitrogen 5.0 (99.999%, GC grade quality) as carrier gas and hydrogen 5.0 as combustion gas. Make sure that the combustion air is dry and free of oil traces. Pure gases prevent the system from contamination. Operating Manual GC 5000 BTX; Version 5 11/

25 4.4 Electrical connections For stand alone operation the analyzer requires an electric mains connection. For remote control operation additional connections like network, USB-, COM- or digital I/O are required. The power cord is included within the scope of delivery. The power supply ( V/50-60Hz) always has to be installed at last. Note Electrical connections are shown on the type plate on the rear panel of the unit. Warning! Electrical parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Therefore make sure that the housing of the GC 5000 BTX is closed before switching on. Operating Manual GC 5000 BTX; Version 5 11/

26 5 Start up 5.1 Safety instructions Warning! Please read following operating instructions carefully before starting operation. Warning! Electrical parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Therefore make sure that the housing of the GC 5000 BTX is closed before switching on. Caution! Hydrogen is combustible and explosive. Disregard may result in damage to the system or cause malfunction and wrong detection results. Therefore avoid wrong gas connections: All gas connections to the GC 5000 are labeled. Make sure that the supply of the gases (hydrogen, nitrogen, combustion air) is secured and the correct port for each gas line is used before switching on the system. Caution! Make sure that the correct gas pressures are used as described in this manual (see paragraph 4.3). Disregard may result in damage to the system. Therefore use the correct pressure values for the gases (hydrogen, nitrogen, combustion air) before switching on the system. Caution! Use nitrogen 5.0 (99.999%, GC grade quality) as carrier gas and hydrogen 5.0 as combustion air. Make sure that the combustion air (zero gas) is dry and free of oil traces. Pure gases prevent the system from contamination. Note! When using synthetic air with a very high purity instead of air from a zero air generator as combustion air make sure that the FID signal-offset of the FID amplifier is adjusted correctly (see chapter ). The FID signal may be lower with synthetic air than with zero air. If the signal is still < 100 mv when the flame is lit, you will get an alarm message (see chapter 14.2 alarm 5.3). Operating Manual GC 5000 BTX; Version 5 11/

27 Note Follow the start up instructions in the mentioned order. Disregard may result in a detector ignition alarm or a carrier gas alarm and the analyzer is not ready for operation. 5.2 Start up instruction Gas pressures Pressure of nitrogen: approx. 3 bar. Pressure of combustion air: 2 bar (necessary for the FID flame). Pressure of hydrogen: approx. 2 bar (necessary for the FID flame). Follow the start up instructions in the mentioned order as described below: 1. Connect all gas lines (as described in chapter 4.2) 2. Connect the digital I/Os, network at the designed ports at the back side 3. If required, connect keyboard and mouse at the front of the analyzer and the monitor at the rear side of the analyzer. 4. Connect main power. 5. Open the gas supply of the carrier gas (nitrogen) and adjust the pressure to approx. 3 bar. 6. While using a FID detector only, adjust the following gas pressures additionally: combustion air supply to 2 bar hydrogen supply to 2 bar 7. Wait until all pressures have stabilized. 8. Switch on the analyzer. The power switch illuminates red. The operating system and the analyzer software start automatically. The warm up starts: All parts of the analyzer get heated to their set points (e.g. detector, GC and valve oven). Using a FID detector the ignition starts 1 minute after reaching 130 C. The analyzer is ready for operation after some minutes of warm up. The status color changes from yellow to green (displayed on the screen in the grey bar at the left side down). Operating Manual GC 5000 BTX; Version 5 11/

28 Note! After switching on the analyzer, it is possible that the enrichment stage heats up to 230 C. This is not a malfunction. It cools down immediately to the specified enrichment temperature. Note! When using synthetic air with a very high purity instead of air from a zero air generator as combustion air make sure that the FID signal-offset of the FID amplifier is adjusted correctly (see chapter ). The FID signal may be lower with synthetic air than with zero air. If the signal is still < 100 mv when the flame is lit, you will get an alarm message (see chapter 14.2 alarm 5.3). Note The colored field indicates the status of the system. Green: the analyzer is ready to start and runs problem-free (see fig. below). Yellow: the system is not ready as set points of the temperatures have not been reached. Red: An alarm or error has occurred. Operating Manual GC 5000 BTX; Version 5 11/

29 5. 3 Decommissioning How to put the analyzer out of operation in case of repair or transportation: 1. Stop program. But do not close the gas lines! 2. Wait until the GC oven has cooled down to 50 C. 3. Shut down the AMA control software and Windows. 4. Switch off the analyzer. 5. Close gas lines now. 6. Disconnect all gas lines from the analyzer. 7. Disconnect the analyzer from the mains supply. Warning! Electrical parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Therefore remove the power cable before opening the device. Note Preparation for a saver shipment: If possible, use the original packaging of the analyzer which is purpose-made. (It contains foamed plastic inserts which are adapted to the size of the analyzer.) Operating Manual GC 5000 BTX; Version 5 11/

30 6 Setting up the GC 5000 Software 6.1 The status screen The AMA control software allows an easy handling of the analyzer. It informs the user via gas flow schemes and alarm windows about active program steps, current pressure and temperatures values etc. If the analyzer is not equipped with a touch screen monitor, a common monitor, mouse and keyboard are required to edit parameters. But this equipment is not necessarily needed for continuous measurements in the field. During operation all important status information will be indicated on this screen. After turning-on the GC 5000 BTX The AMA control software and data acquisition program are automatically loaded. The monitor displays the following status screen: This screen informs about current program steps current status of the system and temperature and pressure values. Two time displays are placed in the lower part of the window: The remaining time for the current program step The time until the next run will start. Note All commands and functions for setting-up and operating the GC 5000 can be activated via pull-down menus (as described in chapter ) Operating Manual GC 5000 BTX; Version 5 11/

31 Colored bar indicates the status The colored field on the left indicates the status of the system: Green The analyzer runs error free and it is ready to start. Yellow Red The system is still not ready. When the GC temperature program has already been started or when the system has just powered up but the set points of the temperatures have not yet been reached. An alarm or error message has occurred. Check the status A click on the colored bar informs about the current status: Click on the yellow or red field: the following status display pops up. All occurred information, alarms and errors are displayed here: Click on the link GC not ready : The next display informs about the current Not ready reasons of the system: Note Potential reasons for the status not ready : 1. Differing temperature values of the GC oven or detector. This is the case within the first 5 minutes after the system has been powered up. 2. When data acquisition has started, the analyzer is always in the status not ready. Operating Manual GC 5000 BTX; Version 5 11/

32 6.2 How to unlock Password protection To avoid an unauthorized access to the parameter editors the AMA control software is equipped with a password protection. Password protection Menu bar Unlock 1. Unlock has to be activated before parameters can be saved. The following window will pop up: 2. Enter the password (as a numeric code) and press E. 3. After modification all parameters can be saved now. Entering a wrong password will cause an error message. Now the menu item Unlock switches to Lock in the menu bar. Note If you do not select a password, i.e. the password is empty, you will not have a password protection. In this case the input window will not pop up and the saving of modifications is enabled immediately without protection. Operating Manual GC 5000 BTX; Version 5 11/

33 6.3 How to select operation modes Menu bar Parameters Operation mode The GC 5000 can be operated in three different operation modes: 1. Manual operation After clicking onto the Start button the analyzer performs one run and waits for the next click onto the Start button. 2. Cyclic mode The analyzer starts the next cycle after the specified cycle time. 3. Remote control The analyzer waits for a new cycle start via the communication protocol (Gesytec II) after each run. 6.4 How to select master mode Menu bar Parameters Master mode If you have an ozone precursors system (one BTX analyzer and one VOC analyzer) you can switch on the master mode and set the VOC analyzer into slave mode. Then the BTX analyzer is the master and controls the VOC analyzer (the slave). Each cycle and the calibrations are started by the BTX analyzer. So the two analyzers are running synchronously. Note It is necessary that both analyzers have the same operation mode, the same number of calibration levels, the same calibration setup and the same validation setup. Operating Manual GC 5000 BTX; Version 5 11/

34 6.5 How to select communication parameters (optional) Analog outputs configuration Menu bar Parameters Analog output conf. If you have a board with 4, 8 or 16 analog outputs in your analyzer, you can edit the configuration and correlation between outputs and results in this window. 1. Select the mode of the desired output type under Analog output type. The resolution of the voltage outputs is 1.22mV and the resolution of the current outputs is 2.7µA. 2. Select for every channel a component from the results file of the chromatography software (Drop-down menu). 3. Edit the low and high range values. Referring to the selected values displayed in the window above, we get the following results : All analog outputs (4) got the type 0-10V. Channel 1: It shows the result for benzene. The output voltage of channel 1 will range linear between 0V for 0ppb benzene and 10V for 10ppb benzene. Channel 2: It shows equivalent 0V for 5ppb toluene and 10V for 100ppb toluene. The same is valid for the channels 3, 4 and 5 for the other components. The channels 6 to 8 will not be used. Operating Manual GC 5000 BTX; Version 5 11/

35 Fig.5: Connection of analog outputs Operating Manual GC 5000 BTX; Version 5 11/

36 6.5.2 Alarm configuration Menu bar Parameters Alarm config. If you have a board with digital outputs in your analyzer, you can edit the configuration of the four alarm outputs in this window. 1. Select the components from the calibration file in the drop-down list. You can configure several alarms for one component. 2. Select the type of alarm (high alarm or low alarm) for each output. 3. Edit the alarm threshold for each output. Note: This concentration must be exceeded / under-run to activate the alarm. If the alarm threshold is 5 ppb and the measurement value is 5 ppb, then the alarm is not activated. Referring to the selected values displayed in the window above, we get the following results: Alarm 1 is activated when the concentration of benzene exceeds 5 ppb. Alarm 2 is activated when the concentration of benzene exceeds 10 ppb. Alarm 3 is activated when the concentration of toluene exceeds 20 ppb. Alarm 4 is activated when the concentration of m,p-xylene falls below 1 ppb. Operating Manual GC 5000 BTX; Version 5 11/

37 6.5.3 Gesytec specifications Menu bar Parameters Remote control Gesytec specifications In this menu you can modify the parameters for the communication via the Gesytec II protocol. Parameters Remote control Gesytec specifications Service mode: The service mode has to be activated before doing maintenance work while the analyzer is operating. Then the analyzer does not accept any control commands from the PC of the monitoring station. In this case controlling is only possible by the analyzers software but results and status are still transmitted Modifying of parameters under Gesytec specifications : Remote control Gesytec specifications COM Parameter: COM Parameter This interface will be used for data transfer between analyzer and monitoring station main computer via the Gesytec II protocol. For this purpose, the transfer speed can be selected in a range of 1200 to Baud. The default value is The Save value menu makes the inputs active. With the Quit button you can leave this window without any change. Operating Manual GC 5000 BTX; Version 5 11/

38 ID Codes Remote control Gesytec specifications ID Code: Using the Gesytec II protocol the analyzer is able to transmit up to 48 results. Codes are combined to 6 blocks of 8 components each. So in accordance to the application, 8, 16, 24, 32, 40 or 48 component data blocks can be transmitted. You have to enter each code here as this protocol needs two codes for calling each result. The serial numbers and ID-codes which are necessary for data transfer have to be edited for each component: The Save menu makes the inputs active. The Quit button leaves this window without any change. Number of components Remote control Gesytec specifications Number of components: Here you can select whether 8, 16, 24, 32, 40 or 48 results are transmitted. The following window pops up: The Gesytec II standard allows only 20 results. If more results have to be transmitted the monitoring stations PC must be able to handle them. See chapter 17. Operating Manual GC 5000 BTX; Version 5 11/

39 Validation/ Calibration on calibration gas on request Remote control Gesytec specifications Validation / Calibration on cal. Gas on request Cal Val In case a calibration run starts via protocol you have to select if the run is handled as a new calibration ( Cal) or validation ( Val, no new calibration data is produced). In both cases calibration valves or modules are switched to the corresponding calibration input or level. Protocol bytes The following charts show the configuration of the data bytes which can be sent from the GC 5000 BTX via the Gesytec II protocol. Control byte Bit 0 Start sampling Bit 1 Zero gas on (calibration gas 1) Bit 2 Span gas on (calibration gas 2) Bit 3 Not used Bit 4 Not used Bit 5 Not used Bit 6 Not used Bit 7 Not used Status byte Bit 0 System off Bit 1 Maintenance / Stand alone mode Bit 2 Zero gas running (calibration gas 1) Bit 3 Span gas running (calibration gas 2) Bit 4 Program step sampling running Bit 5 New results Bit 6 Not used Bit 7 Not ready Error byte Bit 0 Pre-cooling alarm enrichment stage Bit 1 Sample alarm Bit 2 Carrier gas alarm Bit 3 Ignition of FID not possible Bit 4 FID too cold Bit 5 FID too cold for 8 minutes Bit 6 Not used Bit 7 Communication breakdown to MFC / Temp. controller Status and error byte show the current status of the analyzer. Note: The status and error bytes will be transmitted as well. While transmitting results, these status and error bytes indicate the analyzer status during data acquisition only. Operating Manual GC 5000 BTX; Version 5 11/

40 7 Starting operation The required application for your analyzer is already configured by AMA Instruments. So there is no need to develop a method for operation. 7.1 How to start measurements 1. Click onto the start button. Then a small window pops up: 2. If you click on ok: The cycle immediately starts. or 3. If you check Set time for start a new input area appears: 4. Enter the time for the start in the 24 hours format, i.e. 18 o clock means 6 o clock pm. The analyzer waits until this time and then starts the cycle. Operating Manual GC 5000 BTX; Version 5 11/

41 Monitoring of measurement You can monitor the current program step in the program window of the AMA control software after the analyzer has started: When the injection starts, the GC temperature program and acquisition of chromatogram start as well. You can see the real-time chromatogram in the data acquisition window: Operating Manual GC 5000 BTX; Version 5 11/

42 Menu bar View Last results After the chromatogram is completed, you can see the results: Menu bar View Results table All results of the runs are listed: With >copy and paste< you can import the list into an excel file. Operating Manual GC 5000 BTX; Version 5 11/

43 7.2 How to adjust the retention time windows How to load a chromatogram If you find 0.00 results although the peaks are present in the chromatogram, the retention time windows are not at the correct position and have to be adjusted. 1. Menu bar Parameters CP Analysis Load the last chromatogram in the CP Analysis module Note: You should have recorded at least three chromatograms to make sure that the system runs stable now. This means as well that the first run should be discarded. You can load several chromatograms at the same time: Select them in File open dialog with Ctrl/Shift and mouse-click before clicking Open. 2. Menu bar Compare Overlay Mark Overlay in the menu Compare. Overlay of all chromatograms: They are listed on top of each other instead of each one in a separate window. Operating Manual GC 5000 BTX; Version 5 11/

44 3. Menu bar Compare Synchronize Expansion All overlaid chromatograms can be zoomed the same way at the same time. In this window, the overlay is displayed more comfortable. Operating Manual GC 5000 BTX; Version 5 11/

45 How to modify the retention time windows There are two different ways to modify the retention windows: 1. Input new values under Edit Numeric Menu bar Tools Modify Components Edit Numeric or alternatively 2. Drag and click with the mouse under Edit Graphic Menu bar Tools Modify Components Edit Graphic 3. When you click on Edit Numeric a window pops-up after clicking onto a peak name. In this window you can modify name expected retention time half retention window width. In the lower left corner of the screen you can see an additional window with further instructions. Or alternatively 3. By clicking on Edit Graphic some markers appear in the chromatogram: 4. Enlarge or downsize the retention window by dragging of the blue edge markers. Operating Manual GC 5000 BTX; Version 5 11/

46 5. Move the position of the retention window by dragging the lower marker with the peak name inside. How to save window adjustments When all retention windows are adjusted save the new values by clicking Menu bar File Save calibration In this case only the retention times are modified not the response values. Operating Manual GC 5000 BTX; Version 5 11/

47 7.3 How to zoom / zoom out the chromatogram 1st possibility to zoom: In some cases it is difficult to adjust the retention windows in the standard view. 1. Enlarge or downsize the view of the chromatogram by Right-click into the chromatogram window select Scale The following window pops up: 2. Enter the limits of the part of the chromatogram which you want to see in the chromatogram window. 3. Click on OK : This activates the new values and closes the window. Or alternatively Click on Apply : This activates the new values as well but does not close the window. In this case, you can check first if the new values are ok or modify them again before closing this window. Operating Manual GC 5000 BTX; Version 5 11/

48 2nd possibility to zoom: Another possibility to enlarge a part of a chromatogram is the following: 1. Click and hold the left mouse button. 2. Move the mouse by surrounding the part of the chromatogram and release the left mouse button. 3. Activate the zoom by clicking the right mouse button. How to zoom out You can cancel the zoom by Right-click into the chromatogram window Select Undo Expansion Operating Manual GC 5000 BTX; Version 5 11/

49 7.4 How to optimize integration parameters The integration parameters can be optimized if necessary: 1. Load the last chromatograms. 2. Check the integration baseline. In the menu bar Integration you find the commands for moving, adding or deleting integration events. 3. Click on Insert Event. The following window pops up: All possible events with their effects are listed after clicking onto them. 4. Save all adjusted integration parameters: Menu bar file Save method Now the system is ready for measuring operation. Operating Manual GC 5000 BTX; Version 5 11/

50 8.0 Using LCD display and buttons on the front panel Generally the basic version of a GC 5000 Analyzer (BTX or VOC or Process) is equipped with a LCD display and 4 buttons in the front panel. This chapter illustrates the configuration and operation of this LCD display with screenshot examples. The following basic functions can be done without connecting a monitor: start or stop remote control on or off list of errors the results of the last run After power on the analyzer an initialization text will be seen in the display for about 10 seconds. Afterwards the following text appears in the display: First row: informs about the type of analyzer (e.g. GC 5000 BTX). Second row: displays the current program step on the left and on the right about the GC status (ready or not ready). Third row: Fourth row: is reserved for special information. always displays the function of the buttons below. As shown in example above this means: left button: Start or stop of the sample program button Mode : configures the remote control button Results : show the results of the last run button Status : displays occurred errors and the current sample line. Operating Manual GC 5000 BTX; Version 5 11/

51 Button Mode : It displays the current status Remote control Maintenance mode Exit Can be selected or not (done by the left button) Is only available when remote control has been selected (switched on or off with the Maintenance button. Press this button in order to return to the main menu. Button Results : It lists the results of the last run. If there are more than 3 results: scroll the display with the Up or Down buttons Button Exit : Return to the main menu Operating Manual GC 5000 BTX; Version 5 11/

52 Button Status : It displays the next information level: Channel and Errors. Button Channel : It displays the current input channel (sample 1-6, calibration gas 1 2). Some inputs are only available with a calibration gas selector or a sample stream selector. Button Errors : It lists all errors which were detected. In the example below no error message has been detected. Press More : Further error messages are listed if there are any. Operating Manual GC 5000 BTX; Version 5 11/

53 9 Calibrating and validating GC 5000 BTX 9.1 Calibration Calibration intervals A GC 5000 BTX needs to be calibrated from time to time. It depends on the stability of the detector: Note Calibration intervals for GC 5000 BTX: By using a FID detector a three month interval is sufficient, with a PID detector a calibration interval once a month is recommended. A FID detector is very stable and does not have a significant drift after 3 months. Thus it is enough to calibrate the system not more than every three months. A PID detector has a natural drift because of the aging of the PID lamp. Therefore it is recommended to calibrate the system once a month. The AMA control software contains the necessary features for doing the calibration manually or automatically. Operating Manual GC 5000 BTX; Version 5 11/

54 9.2 How to enter the data of calibration gas concentrations Enter the data without a calibration gas module This chapter explains how to enter the concentrations of the span gas cylinder or other calibration levels. Menu bar Parameters Calibration Calibration gas concentration This menu item is only enabled if you do not have a calibration gas module. Whereas a calibration gas module has to be configured in the module setup (see next paragraph 9.2.2). 1. Select a component from the left side and edit the concentration values in all activated levels. 2. Save the values by clicking Save values How to disable concentration levels In case you want to use less concentration levels than are present in the calibration file, you have to disable the concentration levels which are not in use. 1. Remove the check mark from the check box which is left from the level name. The selected concentration level is disabled. This means that it is disabled for all components at once. Note A flame ionization detector (FID) is characterized by its linear detector response. Thus only two concentration levels are required for a proper calibration of the analyzer. By contrast a photo ionization detector (PID) does not show a linear detector response. Therefore a minimum of 4 to 5 calibration levels are recommended for proper calibration of the analyzer. Operating Manual GC 5000 BTX; Version 5 11/

55 9.2.3 Enter the data with a calibration gas module If you have a dilution gas module, this will be configured in the module setup: Menu bar Parameters Module setup Dilution module Calibration gas source concentration setup 1. Enter the concentrations of the source calibration gas cylinder. 2. Select up to four main components out of all components from the calibration file. These up to four components and their concentrations are listed on the display of the DIM 200 (calibration gas module) for all calibration levels. 3. Save your modifications: by clicking Save setup Note: In case you leave the window by clicking the Quit button, the modifications are not saved. 4. When you try to save the new values, the following windows appears first: Operating Manual GC 5000 BTX; Version 5 11/

56 5. Press Yes and the following window automatically pops up: Alternatively you can open this window as follows: Menu bar Parameters Module setup Dilution module Dilution module setup 1. On this window you can enter the concentrations for each calibration level. It is sufficient to enter the concentration for one component or the dilution factor and the other concentrations are automatically calculated. The dilution factor X means that the resulting concentration is 1/X of the source concentration. 2. In the first row you can enable or disable calibration levels but only levels which are present in the calibration file. 3. If you want to have more levels you have to add them with the Chrom Perfect File Editor (See chapter for further information.) 4. After you have entered the correct values, click Save setup to save the parameters. Note A flame ionization detector (FID) is characterized by its linear detector response. Thus only two concentration levels are required for a proper calibration of the analyzer. By contrast a photo ionization detector (PID) does not show a linear detector response. Therefore a minimum of 4 to 5 calibration levels are recommended for proper calibration of the analyzer. Operating Manual GC 5000 BTX; Version 5 11/

57 9.3 How to start a calibration Calibration of one calibration level (with and without calibration module) Manual calibration 1. Start a manual calibration of one calibration level by selecting Menu bar Run calibration Manual calibration Level x 2. Select the calibration level The following window pops up: 3. Select the number of runs for the calibration level and click on the check box if the result of the first run has to be discarded. The calibration of one calibration level is activated. In this example the level is calibrated with the average value of the second and the third run. Operating Manual GC 5000 BTX; Version 5 11/

58 9.3.2 Calibration sequence (without calibration module or cal. valves) The system is configured by AMA Instruments with the following items: o number of runs per level: 1 o the results of the first run is not discarded Setup How to change the pre-configured parameters: 1. Select Menu bar Parameters Calibration Calibration setup 2. Select the number of runs for the calibration level 3. Click on the check box if the result of the first run has to be discarded. The parameters are changed now. Sequence 1. For the run of an auto-calibration without calibration module or built-in calibration valves select: Menu bar Run calibration Manual calibration sequence Prior to each calibration level the following window pops up: 2. Connect the correct calibration gas to the sample port and press Start. After the analyzer did the number of runs, it asks you to connect the next calibration gas to the sample port. 3. Press Start again. The calibration sequence is manually activated. Operating Manual GC 5000 BTX; Version 5 11/

59 9.4 Auto-calibration This paragraph describes the fully automatic calibration for all calibration levels. This function is only activated if the system features built-in calibration gas valves (with up to two calibration levels) or an external calibration gas module (e.g. DIM 200 with up to 20 calibration levels). Menu bar Parameters Calibration Calibration setup 1. Select the number of runs per level between 1 and 9 2. If the results of the first run should be discarded, click on this box. The other parameters are already configured by AMA Instruments. Save the parameters and the auto-calibration can be started. Run of calibration Menu bar Run Calibration Auto-Calibration Here you can start a fully automatic calibration for all calibration levels at once. After the analyzer did the number of selected runs of the first calibration level, it automatically switches to the calibration gas of the next level and does the next runs. The analyzer stops after finishing all runs of the last calibration level. Operating Manual GC 5000 BTX; Version 5 11/

60 9.5 Validation Principle of validation Definition A validation is a run with zero gas and /or a span gas in order to check the drift, repeatability and/or memory effects. The run is treated as a regular sample, i.e. no new calibration data will be produced. System requirements 1. You need built-in calibration valves or a calibration gas module to do a validation. 2. Type of gas: The gas for the validation may not be the same which is also used for the calibration of the system. You can use a gas with only one of the components from the calibration file Types of validation Initial validation The initial validation produces the original data which is needed for the calculations as the results of the standard validation are compared with the values of the initial validation e.g. a drift check has been performed. An initial validation has to be done before a standard validation runs for the first time. after a calibration has been performed. when the validation gas has been changed Menu bar Run validation Initial validation After selection of this menu item the analyzer starts doing the initial validation. It stops after the validation is completed. Standard validation Menu bar Run validation standard validation Here you can start a standard validation. If you select this menu item the analyzer starts to do the standard validation. The analyzer stops after the validation is completed. The analyzer runs an automatic validation as well if configured in the validation setup: Menu bar Parameters Validation setup This menu item is only activated if the analyzer is equipped with built-in calibration valves or it has been connected to an external calibration module. Operating Manual GC 5000 BTX; Version 5 11/

61 9.5.3 How to start validation 1. Step: Configuration Configure the type of tests the system should do: 1. Select the menu item Validation setup Menu bar Parameters Validation setup 4 types of validation tests 2. Click on the relevant boxes the type of tests which should run: Zero gas check Drift check Deviation value Run auto-validation It checks for memory effect or contamination It checks for a deviation between the original span value and the current span value It checks for a deviation between two current span values If a validation shall start automatically either after a number of cycles or at a definite time. 3. Select the zero gas supply and the span gas supply: These items select the corresponding inputs when using calibration valves or the corresponding levels when using a calibration module. 4. Select the relevant components for the validation Menu bar Select components Operating Manual GC 5000 BTX; Version 5 11/

62 Explanation to the entries in this window: 1. First column: Select the components which shall be included in the validation. 2. Second column: List the names of the components. 3. Other columns: Here you can specify the limits for the warning level or for the error level. The configuration of the tests is completed. Definition Warning level: You get a message if it is reached but the program will continue. A warning level in the drift check can be used to do an auto-calibration. Error level: You get a message and the program will stop because the system must have a problem which should be fixed first. Example of limits for warning and error levels: In the window above the following example lists the limits which are defined as warning and error levels for benzene. Zero gas check Warning level 0.3 ppb Error level 0.6 ppb Drift check Warning level 5% Error level 10% Deviation check Warning level 2% Error level 4% Operating Manual GC 5000 BTX; Version 5 11/

63 2. Step: Run initial validation How to run initial validation: 1. Select Menu bar Run validation Initial validation Note Before running a standard validation for the first time, an initial validation has to be performed. As well it is necessary to run an initial validation after each calibration. An initial validation has to be performed at any time, when the validation gas has been changed. Automatic initial validation Depending on the setting for run initial validation after auto-calibration or manual sequence (see check box on window below) the analyzer will run automatically an initial validation either directly when a calibration sequence has been completed or during the next scheduled validation run. 3. Step: Standard validation How to run standard validation: There are two possibilities to run a standard validation. It depends on whether to run it manually or automatically. 1. Start a run manually: select Menu bar Run validation Standard validation Alternatively: 2. Start an automatic run: Press the Start button on the main screen. The validation starts after the specified cycles or time as this parameter have been set in the validation setup. Operating Manual GC 5000 BTX; Version 5 11/

64 3. Check validation status: Select Menu bar View Validation status In this window the result is displayed after a validation sequence has completed. In the example below every check is within the defined limits. Green indicates that the validation run of all tests is ok. Yellow indicates that the limit is reached (warning level) Red indicates that the values exceed the limit (error level). For further information and definition see page Check the exact results by opening e.g. the file c:\cpdata\gc5000\valbenzene.btx.met.txt in case Benzene has been used for validations. Note The name of the file consists of VAL + component name + method name +.txt. Structure of file: The columns of the file contain the following information: Counter I for initial validation / S for standard validation Name of chromatogram for zero gas check Date and time of chromatogram for zero gas check Result of chromatogram for zero gas check Name of chromatogram for drift check Date and time of chromatogram for drift check Result of chromatogram for drift check Name of chromatogram for deviation check Date and time of chromatogram for deviation check Result time of chromatogram for deviation check Drift Deviation Operating Manual GC 5000 BTX; Version 5 11/

65 Calculation basis of deviation and drift: The result of the zero gas run is equal the zero gas deviation. The drift is calculated from the difference from the actual result and the result from the initial validation. The deviation is calculated from the difference of two actual results (chromatogram for drift check and chromatogram for deviation check). Operating Manual GC 5000 BTX; Version 5 11/

66 10 Functional description 10.1 Measuring principle This chapter refers especially to personnel who is in charge of maintenance work or applications. The AMA BTX Analyzer is a system for automatic sampling, enrichment and GC analysis, regarding the following organic substances: The measurement is based on the principle of adsorption of compounds on special materials in an enrichment tube and detection of the organic compounds with the help of a FID or a PID detector after separation on a capillary column of a GC. Fig. 6: Time program (example): Steps of operation: 1. Purging time sample line: The sample line is purged with sample gas to make sure that actual sample gas is available when starting the next step. 2. Enrichment on the BTX-tube: A definite volume of ambient air (regulated flow with a thermal mass flow controller, in the further text always called MFC) is sucked through an enrichment tube (BTX-tube), which is filled with adsorbent material. 3. Injection: After enrichment the BTX-tube is heated in a very fast way and the adsorbed materials are vaporized again and flushed onto the capillary column of the gas chromatograph module. Operating Manual GC 5000 BTX; Version 5 11/

67 4. Separation by gas chromatography and Analysis of data: A gas chromatographic capillary column is used to separate the sampled objects. The separated compounds are detected by a FID or a PID. The measured peak areas can be compared with the function of calibration. 5. Waiting for cycle time and cooling down the BTX-tube: Before the next start of sampling the enrichment stage is cooled down to the enrichment temperature Definition of the program parameters 1. Purging time: The sample line will get flushed with sample or calibration gas for this time. 2. Enrichment temperature: The enrichment stage has to be cooled down to this value (+/-5 C) before the sampling will get started automatically. 3. Sampling time: During this time the programmed sample volume has to be sucked through the enrichment stage. 4. Sample volume: This is the set point of the volume which has to be sucked through the enrichment stage during sampling. 5. Calculated gas flow: The shown value of the sucking velocity during sampling is calculated as the quotient of the sample volume and the sample time less 10 seconds. This subtraction is made to get a little time buffer for starting the MFC. Note The value will be calculated after saving the set points as current values, before the previous value is shown. 6. Injection temperature: The enrichment stage will be heated to this temperature value during the program step injection. 7. Injection time: The vaporized sample will be transferred from the hot enrichment stage to the GC column during this program step. Simultaneously the GC temperature program and the data acquisition are started. 8. Cycle time: The cycle time is the time between two starts of sampling. Operating Manual GC 5000 BTX; Version 5 11/

68 9. Valve oven temperature: The valve oven will get heated to this temperature value. It has to be in the range of +40 C to +150 C. 10. Detector temperature: The detector will get heated to this temperature value. It has to be in the range of +130 C to +200 C for a FID detector or in the range of +40 C to +150 C for a PID detector. 11. Hydrogen flow: If you have a FID you can enter the hydrogen flow for the detector here. The flow is regulated by a mass flow controller. The range is from 25 ml/min to 75 ml/min. Standard is 40 ml/min. 12. Chrom Perfect method In this menu item you can select the method for the chromatographic analysis. See chapter for more information about the Chrom Perfect method. Operating Manual GC 5000 BTX; Version 5 11/

69 10.3 Program example After starting the sample program the pump will get started and the sample line will get flushed for two minutes (purging time) with sample gas. Simultaneously the enrichment tube will be cooled down to 30 C (sampling temperature). Next VE1 is switched and sampling starts with a flow of 21ml/min (calculated gas flow) until a volume of 300ml (sample volume) is sucked through the enrichment tube. Now the CP method (sample or calibration) is loaded and VE1 is switched back. The enrichment tube gets heated very quickly up to 230 C (Injection temperature). Simultaneously the GC oven program is started and data acquisition begins. 3 minutes (Injection time) later the enrichment tube starts to cool down to the sampling temperature of 30 C and the system is ready for the next start. This start may occur before the GC oven temperature program was finished. Operating Manual GC 5000 BTX; Version 5 11/

70 11 Software reference 11.1 Basic software design Software architecture The software of the GC 5000 consists of two parts, the controlling software GC 5000 BTX and the chromatography software Chrom Perfect. All functions of the system are controlled via the GC 5000 BTX software, except modification of retention windows, integration parameters as well as reintegration of chromatograms The Chrom Perfect software records the chromatograms, analyzes them und passes the results via a file link to the GC 5000 BTX program. Note Do never close the Chrom Perfect data acquisition window after switching on the analyzer as the DDE connection between both programs would be broken. This mistake causes an error message while the AMA control software stops immediately. After 30 seconds the hardware watchdog restarts the internal PC again automatically Configuration files There are three different configuration files: GC 5000 method file (.mth) Chrom Perfect method file (.met) Chrom Perfect calibration file (.cal). GC 5000 method Chrom Perfect method Chrom Perfect calibration file It contains all necessary parameters for the controlling of the GC 5000, like temperatures, program step times, the GC oven program and the name of the Chrom Perfect method. It contains all necessary parameters for the recording and analysis of the chromatogram and the name of the Chrom Perfect calibration file. It contains the component table with the retention times and the calibration data like fitting type and response values. Operating Manual GC 5000 BTX; Version 5 11/

71 Main window: Program This is the most important window of the AMA control software and normally the one, which is displayed on the screen. 1. This window informs about the current program step, the current status of the system and the temperature and pressure values. 2. Two time displays are placed in the lower part of the window.: The first one displays the remaining time for the current program step The second one displays the time until the next run will start. 3. The menu bar on top of the screen list the menu items. These are described in detail in this chapter. 4. The colored field on the left indicates the status of the system: Green Yellow Red The analyzer runs error free and it is ready to start. The system is still not ready. When the GC temperature program has been already started or when the system has just powered up but the set points of the temperatures have not yet been reached. An alarm or error message has occurred. A click on the bar informs about the current status details (see next page). Operating Manual GC 5000 BTX; Version 5 11/

72 Check on the status bar A click on the yellow or red field opens the status display. All occurred alarms and errors will be shown here: Clicking the button GC not ready : It informs about the Not ready reasons of the system. Note Potential reasons for not ready : 1. Differing temperature values of the GC oven or detector. This is the case within the first 5 minutes after the system has been powered up. 2. When data acquisition has started, the analyzer is always in the status not ready. Operating Manual GC 5000 BTX; Version 5 11/

73 Menu items The menu bar of the main window above contains the following menu items: Unlock Parameters Program steps View Run calibration Run validation Help They are described in detail on the following pages in the following chapters. Operating Manual GC 5000 BTX; Version 5 11/

74 11.2 Unlock The AMA control software is equipped with a password protection to avoid an unauthorized access to the parameter editors Menu bar Unlock has to be activated before modifications of parameters can be saved. The following window pops up: 1. Enter the password (as numeric code) and press E. 2. After modification all parameters can be saved now. Entering a wrong password will cause an error message. Note If you do not select a password, i.e. the password is empty: In this case the input box will not pop up. The saving of modifications is enabled but without protection. Note Before starting the CP File Editor or CP Analysis Unlock has to be activated. Otherwise these menu items are disabled. Operating Manual GC 5000 BTX; Version 5 11/

75 11.3 Parameters In this menu item you can edit parameters like temperatures or times. Menu bar Parameter Select between the following parameters: Change password Operation mode Remote control Master mode Method Analysis GC oven Calibration Validation setup Analog output configuration CP Analysis CP File Editor Module setup Change password Operation mode Menu bar Parameter Change password When you click on Change password the earlier described input box pops up (see chapter ). Enter the new code and click onto E. The new password is active now. Menu bar Parameter Operation mode In this menu item you can select between three different modes: Manual operation : The analyzer starts one run after clicking onto the Start button and waits for the next click onto the Start button. Cyclic mode : The analyzer starts the next cycle after the specified cycle time. Remote control : The analyzer waits for a new cycle start via the communication protocol after each run. Operating Manual GC 5000 BTX; Version 5 11/

76 Remote control Menu bar Parameter Remote control In this menu item you can modify the parameters for the communication via the Gesytec II protocol. Parameters Remote control Gesytec specifications Service mode: The service mode has to be activated before doing maintenance work while the analyzer is operating. Then the analyzer does not accept any control commands from the monitoring stations PC. Controlling is only possible by the analyzers software. Results and status are still transmitted. Menu bar Parameter Gesytec specifications The following parameters can be modified: COM Parameter Remote control Gesytec specifications COM Parameter This interface will be used for data transfer between analyzer and main computer of the monitoring station via the Gesytec II protocol. For this purpose, the transfer speed can be selected in a range of 1200 to Baud. The default value is Clicking on menu item Save value makes the inputs active. With the Quit button you can leave this window without any change. Operating Manual GC 5000 BTX; Version 5 11/

77 ID-Codes Remote control Gesytec specifications ID-Codes Using the Gesytec II protocol the analyzer is able to transmit up to 48 results. Codes are combined to 6 blocks of 8 components each. So in accordance to the application, 8, 16, 24, 32, 40 or 48 component data blocks can be transmitted. As this protocol needs two codes for calling each result you have to enter each code in the following window: The serial numbers and ID-codes which are necessary for data transfer have to be edited for each component: Clicking on menu item Save value makes the inputs active. With the Quit button you can leave this window without any change. Number of components Remote control Gesytec specifications Number of components: The following window pops up: 1. Select the number of transmitted results: 8, 16, 24, 32, 40 or 48. The Gesytec II standard normally allows only 20 results. If more results are to be transmitted PC of the monitoring stations must be able to handle them. See chapter 17. Operating Manual GC 5000 BTX; Version 5 11/

78 Validation/ Calibration on calibration gas on request Protocol bytes Remote control Gesytec specifications Validation / Calibration on cal. Gas on request Cal Val In case a calibration run starts via protocol you have to select if the run is handled as a new calibration ( Cal) or validation ( Val). In case of selection Validation no new calibration data is produced. In both cases calibration valves or modules are switched to the corresponding calibration input or level. Gesytec specifications Protocol bytes The following charts show the configuration of the data bytes which can be sent from the GC 5000 BTX analyzer via the Gesytec II protocol. Control byte Bit 0 Start sampling Bit 1 Zero gas on (calibration gas 1) Bit 2 Span gas on (calibration gas 2) Bit 3 Not used Bit 4 Not used Bit 5 Not used Bit 6 Not used Bit 7 Not used Status byte Bit 0 System off Bit 1 Maintenance / Stand alone mode Bit 2 Zero gas running (calibration gas 1) Bit 3 Span gas running (calibration gas 2) Bit 4 Program step sampling running Bit 5 New results Bit 6 Not used Bit 7 Not ready Error byte Bit 0 Pre-cooling alarm enrichment stage Bit 1 Sample alarm Bit 2 Carrier gas alarm Bit 3 Ignition of FID not possible Bit 4 FID too cold Bit 5 FID too cold for 8 minutes Bit 6 Not used Bit 7 Communication breakdown to MFC / Temp. controller Status and error byte show the current status of the analyzer. Note: The status and error bytes will be transmitted as well. While transmitting results, these status and error bytes indicate the analyzer status during data acquisition only. Operating Manual GC 5000 BTX; Version 5 11/

79 Master mode Menu bar Parameter Master mode If you have an ozone precursors system (one GC 5000 BTX analyzer and one GC 5000 VOC analyzer) you can switch on the master mode and set the VOC analyzer into slave mode. In this case the BTX analyzer is the master and controls the VOC analyzer (the slave). Each cycle and calibrations are started by the BTX analyzer. So the two analyzers are running synchronously. Note It is necessary that both analyzers have the same operation mode, the same number of calibration levels and the same calibration setup. In case a complete ozone precursor system (GC 5000 BTX and GC 5000 VOC) is manufactured at the same time by AMA Instruments, the parameters are configured ex factory Method Menu bar Parameter Method The current set of parameters can be saved as a method or a new set of parameters can be loaded. The following window pops up: 1. Select a saved method and after clicking onto Open it is loaded. 2. Analog you can save a set of parameters as a method with clicking onto Save. Operating Manual GC 5000 BTX; Version 5 11/

80 Analysis Menu bar Parameter Analysis The following window pops up: Every value of the sample and enrichment program which can be modified is displayed in this window. These are: Different times as sampling or injection time in minutes and seconds, cycle time in hours, minutes and seconds. Sample volume, the temperature values for the enrichment tube, the valve oven and the detector can be modified. How to change any value: 1. Click on its input field, e.g. sampling time (see window above). The following numeric window pops up and you can enter the new value. In the upper part the value is displayed in the box. 2. Enter the new value in the box and press E (enter) 3. Save the parameters after editing: Menu item Save as actual values Note 1. In case that all values are in the permitted range, the analyzer will accept them immediately and the parameter window will get closed. 2. If a value is erroneous (e.g. a temperature value is too low or too high) an error message will occur and the old values will stay active. Operating Manual GC 5000 BTX; Version 5 11/

81 GC Oven Menu bar Parameter GC oven The following window pops up: Every value of the GC program which can be modified is displayed in that window. These are the initial temperature the initial time for the first phase values for heating rate final temperature final time for the next three phases. How to calculate the new total time of the GC program: 1. Modify any value by clicking on the relevant input box. 2. Enter the numeric field in the numeric window and press enter E. 3. Click on the button Calculate The edited GC program will be calculated and the total time will be displayed. Attention: The values have not been saved yet. How to display a diagram of the GC program: 1. Modify any value by clicking on the relevant input box. 2. Enter the numeric field in the window and press enter E. 3. Click on the button Diagram The modified diagram will be displayed: Operating Manual GC 5000 BTX; Version 5 11/

82 How to run a GC oven program with less than 3 heating ramps: 1. Set the heating rate for the first not used temperature phase to zero. In the example above the GC program finish after the end of final time 1. Note Check the starting temperature of the GC oven program. The ambient temperature during operation of the instrument has to be at minimum 10 C below the starting temperature of the GC oven program in order to guarantee reliable cooling down of the GC oven at the end of each cycle. Operating Manual GC 5000 BTX; Version 5 11/

83 Calibration Menu bar Parameter Calibration You can select between: Calibration setup Calibration gas concentration Calibration setup Menu bar Parameter Calibration calibration gas setup The AMA GC-5000 control software features a calibration setup. If the optional calibration gas valves are installed, this software part controls them: 1. Connect zero gas and span gas to the appropriate inputs of the analyzer (see chapter 3.5.1). If an external calibration gas unit like a permeation module or a dilution module is connected, the module has priority over the internal valves and the module controls the calibration levels. (See chapter for more details about gas calibration modules.) 2. Select the number of cycles per calibration level. 3. Place a check mark to discard the first run per level if the results of the first run for each level always should be discarded. 4. Place a check mark at run auto calibration in this window if the analyzer should run it. Another check box appears as there are three possibilities now to run an auto-calibration: after a specified number of cycles at a specified time or when the validation drift check exceeds the warning level Operating Manual GC 5000 BTX; Version 5 11/

84 According to the example in the window above, the following entries describe an auto-calibration after a specified number of cycles: 5. Select the radio button Number of sample cycles. In this example the analyzer runs 50 sample cycles 2 runs for each calibration level discards the first run of each level. Then the analyzer will do 50 sample cycles again. Alternative: to run an auto-calibration at a specified time as it is displayed in the window below: 6. Select the radio button Date/Time Another input data area auto calibration setup appears as displayed below: 7. Select the following parameter in that input data area period between calibrations date day and time if necessary. Note The input of the time has to be entered in a 24 hours format, i.e. 10 o clock pm has to be entered as 22 o clock. Operating Manual GC 5000 BTX; Version 5 11/

85 Calibration gas concentration Menu bar Parameter Calibration calibration gas concentration This menu item is only visible if you do not have connected a calibration gas module. Enter the concentrations in the span gas cylinder or other calibration levels in this window: 1. Select a component from the left side and 2. Edit the concentration values in all selected levels. 3. Save the values by clicking Save values. Disable calibration levels It is possible to disable a calibration level as well: 1. Remove the check mark from the check box left from the level name. The selected concentration level is disabled. This means that it is disabled for all components at once. Note A flame ionization detector (FID) is characterized by its linear detector response. Thus only two concentration levels are required for a proper calibration of the analyzer. By contrast a photo ionization detector (PID) does not show a linear detector response. Therefore a minimum of 4 to 5 calibration levels are recommended for proper calibration of the analyzer. Adding components /levels If you want to add components or levels you have to use the Chrom Perfect File Editor (See chapter for further information.). Operating Manual GC 5000 BTX; Version 5 11/

86 Validation setup Menu bar Parameter Validation setup The following window pops up: Here you can configure all parameters for auto-validations. The validation setup is described in chapter 9.5. Operating Manual GC 5000 BTX; Version 5 11/

87 Analog output configuration Menu bar Parameters Analog output conf. If you have a board with 4, 8 or 16 analog outputs in your analyzer, you can edit the configuration and correlation between outputs and results in this window. How to configure the output signals Only that number of channels is editable which are present. 1. Select the mode of the desired output type under Analog output type. The resolution of the voltage outputs is 1.22mV and the resolution of the current outputs is 2.7µA. 2. Select for every channel a component from the results file of the chromatography software (Drop-down menu). 3. Edit the low and high range values. Referring to the selected values displayed in the window above, we get the following results: All analog outputs (4) got the type 0-10V. Channel 1: It shows the result for benzene. The output voltage of channel 1 will range linear between 0V for 0ppb benzene und 10V for 10ppb benzene. Channel 2: It shows equivalent 0V for 5ppb toluene und 10V for 100ppb toluene. The same is valid for the channels 3, 4 and 5 for the other components. The channels 6 to 8 will not be used. Operating Manual GC 5000 BTX; Version 5 11/

88 Fig.5: Connection of analog outputs Alarm configuration Menu bar Parameters Alarm config. If you have a board with digital outputs in your analyzer, you can edit the configuration of the four alarm outputs in this window. 1. Select the components from the calibration file in the drop-down list. You can configure several alarms for one component. 2. Select the type of alarm (high alarm or low alarm) for each output. 3. Edit the alarm threshold for each output. Note: This concentration must be exceeded / under-run to activate the alarm. If the alarm threshold is 5 ppb and the measurement value is 5 ppb, then the alarm is not activated. Operating Manual GC 5000 BTX; Version 5 11/

89 Referring to the selected values displayed in the window above, we get the following results: Alarm 1 is activated when the concentration of benzene exceeds 5 ppb. Alarm 2 is activated when the concentration of benzene exceeds 10 ppb. Alarm 3 is activated when the concentration of toluene exceeds 20 ppb. Alarm 4 is activated when the concentration of m,p-xylene under-runs 1 ppb. Note If you select a new Chrom Perfect method in the analysis parameter window, all alarms are set to the first component, high alarm and 0 alarm threshold for security reasons CP Analysis Menu bar Parameter CP Analysis You can start the Chrom Perfect Analysis module with this menu item. In the Analysis module saved chromatograms can be viewed or evaluated. You can also change the integration parameters or modify the retention time windows. See chapters for detailed information. Note Before starting the CP Analysis or CP File Editor the menu item Unlock in the menu bar has to be activated. Otherwise these menu items are disabled. Operating Manual GC 5000 BTX; Version 5 11/

90 CP File Editor With the CP file editor we can modify Chrom Perfect method files and calibration files. Note Before starting the CP File Editor or CP Analysis the menu item Unlock in the menu bar has to be activated. Otherwise these menu items are disabled. Menu bar Parameter CP File Editor 1. Start the Chrom Perfect File Editor by selecting this menu item. The following windows pops up: 2. For editing a method click on the left upper button, for editing a calibration file click on the right upper button to open a corresponding file. 3. The other file types are not needed. How to edit method files, see next pages. Operating Manual GC 5000 BTX; Version 5 11/

91 How to edit method files Menu bar Parameter CP File Editor Press the button Method file (MET) The window below pops up: Method (.MET) files contain directions for acquiring data and processing chromatogram files (.RAW). In the following chapter the different configurations of each tab (as displayed below) are described. Acquisition tab: On this tab you can configure o the length of a chromatogram (Run time) o the recording frequency (Data samples per second) o the limits of the standard view of the real time plot (high scale, low scale). Events tab: On this tab you can set integration events. This can be easier done in the Analysis module (see chapter 7.4). These parameters are preconfigured by AMA Instruments as well. Operating Manual GC 5000 BTX; Version 5 11/

92 Processing tab: On this tab you can configure o the peak detect threshold o the minimum peak width o the calibration file to use. Definition of the peak detection threshold: The Initial peak detection threshold tells the peak-detection algorithm how much noise may be expected in the chromatogram. This number is dimensionless. Appropriate values range from -6 to +28: If the value is too large, then peaks will be treated as noise, and missed. If the value is too small, then noise will be treated as peaks, and the chromatogram will be littered with false peaks. How to determine the threshold: 1. Select context menu measure noise in a real time plot or a loaded chromatogram. The program will tell you the noise and the recommended threshold. Operating Manual GC 5000 BTX; Version 5 11/

93 Report tab: On this tab you can specify reports which shall be created. Note This part has been already configured by AMA Instruments. Do not modify or delete these two files: last_results2.fmt and results.fmt. They are necessary for a working data transfer to the GC 5000 software! Plot tab: On this tab you can set the limits of the standard view when loading a chromatogram in the Analysis module. Operating Manual GC 5000 BTX; Version 5 11/

94 Plot options tab: On this tab you can configure which details you want to see in a real time plot or in a printed chromatogram. Operating Manual GC 5000 BTX; Version 5 11/

95 How to edit calibration files Menu bar Parameter CP File Editor press the button Calibration file (CAL) Calibration files contain the information to identify components and to calculate their concentrations. Component tab: Calibration file (CAL) Component tab: The spreadsheet at the top of the window displays the component information, one row for each component: The column called component name contains the name that appears in plots and reports. Every component has to be identified with a welldefined name, i.e. the name must be unique. The columns called Retention time, Window width, Reference component determine the interval of retention time. This interval identifies a peak as the relevant component. Every component must have an unique retention time. Example: If the retention time is 12 minutes and the window width is one minute, then the peak may elute anywhere between 11 and 13 minutes. How to prevent that a component's retention time changes during an update: double-right-click on the retention time cell to toggle the cell of the update status to the frozen status. The background color of the cell turns red when changing in the frozen status. The column ref. comp.# you can select a reference component. Then the retention window of the component is shifted according to a retention time shift of the reference peak. Operating Manual GC 5000 BTX; Version 5 11/

96 The column Fit Type specifies the kind of calibration curve that will be fitted to the data points. The column Origin specifies whether the calibration curve will ignore the origin, or it will be forced to pass through the origin, or it will be extrapolated to the origin. The fit type and origin settings together determine the number of distinct (not replicate) data points that must be present. This table shows the minimum number or data points required for each choice of fit type and origin. Type of fit Ignore or Extrap Zero Force Zero Point-to-point (PTP) N/A 1 Linear 2 1 Quadratic (Quad) 3 2 Cubic 4 3 Power N/A 2 The column called Quant (quantification) determines which peak property is taken as the source of the data points. The parameter are height, area, multipeak height, and multipeak area. Note: The first two parameters height and area are the most frequently used. Area usually gives more reproducible results than height for wellresolved peaks. However, when peak separation is poor, height can be more accurate than area. Special case of quantification: The two other quantification types - multipeak area and multipeak height - base the response on the sum of the areas or heights of all of the peaks that fall within the component s search window. Note: These types of quantification are useful in aggregate hydrocarbon analysis when you want the sum of all peaks in a window. The columns Level amount and Level Response occur in pairs, one for each level in the calibration file.. Operating Manual GC 5000 BTX; Version 5 11/

97 We now turn to the control buttons below the spreadsheet. The two radio buttons ( external / internal standard) determine whether the calibration file will use external or internal calibration. The GC 5000 BTX will always use external calibration. The Default Component list box determines which component, if any, will be used to quantify peaks that are not identified as components. How to change a number of components There are three possibilities: 1. Increase the number of components: Select a component (row) and press the Insert Comp button. Each press will generate a new row after the selected row. The contents of the selected row will be copied into the new row, except for the component name, which will read "[New]". 2. Insert a component before the first row: Select the upper left corner of the spreadsheet instead of a row. In this case, the new entries will be blank. 3. Remove a component: Select it and press the Delete Comp button. The selected row will vanish. How to change a number of levels There are three possibilities: 1. Increase the number of levels: Select an existing level (either column) and press the Insert Level button. Each press will generate a new level (two columns) after the selected level. The contents of the new level will be zero. 2. Insert a level before the first level: Select any non-level column. 3. Remove a level: Select it and press the Delete Level button. The selected column pair will vanish. Copy How to copy the contents of one cell to those below it: Select a block of cells and press the Copy Down button. Operating Manual GC 5000 BTX; Version 5 11/

98 Calibration file (CAL) Misc options tab: Signification of the boxes in the window above: Creator and Description boxes are for documentation purposes only. These fields normally contain the developer's name and the description of the method. They will appear on the printout, but have no other effect. Area reject value determines a minimum peak area. Peaks with less than this area will be omitted from the report. If the plot shows baselines, such peaks will have a baseline, but not the retention time or other peak labels. Reference peak area reject It determines a minimum peak area for a reference peak. Peaks with less than this area will not be used as retention time references. If a peak of a reference component fails to meet this threshold, it will not be used as reference peak. Then the retention time windows of the depending components will remain in their original positions. Amount units box Its content may be printed on formatted reports, but does not affect the numeric values. Weighting method for averaging This radio button must be set to Equal weight for all updates as this is necessary for a correct averaging. Otherwise the result after a calibration with more than two runs per calibration level is not as expected. Operating Manual GC 5000 BTX; Version 5 11/

99 Subsequent calibration Calibration file (CAL) Misc options tab Perform an update: The following window pops up: How to process new calibration data subsequently from an already acquired chromatogram: The relevant data input is displayed in the window above. 1. Specify the correct calibration level in the field Level to update. 2. Select one the three radio buttons on the left which determine the type of update. 3. Click on one of the two radio buttons on the right. Select whether the new data shall be used or whether the old and the new data shall be averaged. 4. Select the name of the corresponding chromatogram in the field Bound File Name. 5. Click onto OK. The data has been produced. 6. Select Component tab On this tab you can check the new retention times and/or the new response values. 7. At last the component table shall be saved again by clicking Menu item File Save The data has been saved Module setup Menu bar Parameter Module setup In this menu you can configure connected AMA Instruments modules like a sample stream selector, a dilution module or a permeation module. The module setup is described in detail in chapter Operating Manual GC 5000 BTX; Version 5 11/

100 11.4 Program steps Standard BTX Menu bar Program steps All program steps of the analyzer can be checked up here. It requires that the sample program has already been stopped. Program steps: Program stopped Purging of sample line Sampling Waiting for GC Ready Injection Waiting for end of cycle time If the sample program is running, this menu item is disabled. In this case the current program step is always shown real-time on the monitor. Program stopped Operating Manual GC 5000 BTX; Version 5 11/

101 Purging of sample line Sampling Waiting for GC Ready Operating Manual GC 5000 BTX; Version 5 11/

102 Injection Waiting for end of cycle time Operating Manual GC 5000 BTX; Version 5 11/

103 BTX with stripper column Menu bar Program steps All program steps of the analyzer can be checked up here. It requires that the sample program has already been stopped. Program steps: Program stopped Purging of sample line Sampling Waiting for GC Ready Injection Waiting for end of cycle time If the sample program is running, this menu item is disabled. In this case the current program step is always shown real-time on the monitor. Program stopped Operating Manual GC 5000 BTX; Version 5 11/

104 Purging of sample line Sampling Waiting for GC Ready Operating Manual GC 5000 BTX; Version 5 11/

105 Injection Waiting for end of cycle time Operating Manual GC 5000 BTX; Version 5 11/

106 11.5 View Menu bar View It displays the following menu items: Events Last results Result table Validation status GC oven program. Events Menu bar View Events Every event of interest will be saved in the event.log file with date and time. For example: Alarms like FID flame off, carrier gas pressure below minimum, power failure etc. The reset of alarms as described above. Standard events like cycle start or program Stop. Use the menu items to save or to print or to clear the event.log file. Operating Manual GC 5000 BTX; Version 5 11/

107 Last results Menu bar View Last results This window displays the results of the last cycle. Result Table Menu bar View Results This window displays the results of all cycles. Operating Manual GC 5000 BTX; Version 5 11/

108 Validation status Menu bar View Events This window displays the current validation status. In this example every check is within the defined limits. o o o Green indicates that the validation run of all tests is ok. Yellow indicates that the warning level has been reached Red indicates that the error level has been reached. (See page for further information about warning and error levels and the different types of validation tests.) GC oven program Menu bar View GC Oven Program This window displays the diagram of the GC oven program and its current status: It displays if the GC oven program is running the current GC oven temperature the remaining time for the current temperature program. It displays the GC ready status: If the status is not ready (status field color is yellow or red), then click on the status field for detailed information. Operating Manual GC 5000 BTX; Version 5 11/

109 11.6 Run calibration (manual and auto-calibration) Menu bar Run Calibration With the help of this menu item you can start a manual or automatic calibration. Note: The standard sample program has to be stopped first. Manual calibration Menu bar Run Calibration Manual Calibration This menu item enables to start a manual calibration of only one calibration level. 1. Select one calibration level of the list. The following window pops up: 2. Select the number of runs for this calibration level 3. If the result of the first run is to be discarded mark that check box. 4. Press ok. In this example the level is calibrated with the average value from the 2nd and 3rd run. Manual calibration sequence Without a calibration module or built-in calibration valves, this is the possibility to run an auto-calibration. Only the connection of the calibration gas to the sample port has to be done manually: Menu bar Run Calibration Manual Calibration Sequence 1. Before each 1 st run of a calibration level, you are asked to connect the correct calibration gas to the sample port and then press Start. 2. After the analyzer did the number of runs it asks you to connect the next calibration gas to the sample port and press Start again. Operating Manual GC 5000 BTX; Version 5 11/

110 Note The items like number of runs per level and if to discard the results of the first run is configured in Menu bar Parameter Calibration Calibration setup (See chapter ) Autocalibration Menu bar Run Calibration Auto-Calibration Here you can start a fully automatic calibration for all calibration levels at once. After the analyzer did the number of runs it automatically switches to the calibration gas for the next level and does the next runs. The analyzer stops after the runs for the last calibration level. This function is only enabled if you have built-in calibration gas valves and only two calibration levels or an external calibration gas module with up to 20 calibration levels. Calibration setup: Menu bar Parameters Calibration Calibration setup The number of runs per level and if to discard the results of the first run is configured in the calibrations setup. (See chapter for detailed information). Operating Manual GC 5000 BTX; Version 5 11/

111 11.7 Run validation General The definition of a validation and the validation setup are described in chapter 9.5. Note: The analyzer has to be stopped before starting a validation with this menu. These menu items are only enabled if you have built-in calibration gas valves or an external calibration gas module Initial validation Menu bar Run validation Initial validation Here you can start an initial validation. You have to do an initial validation after a new calibration or when you changed the validation gas. After selecting this menu item the analyzer starts to do the initial validation. The analyzer stops after the run is completed. Standard validation Menu bar Run validation Standard validation Here you can start a standard validation. After you have selected this menu item the analyzer starts to do the standard validation. The analyzer stops after the run is completed. Test Menu bar Run validation Test Level or input Here you can start a test sample of a calibration level when using a calibration module or an input when using calibration valves. The analyzer stops after the run is completed. Operating Manual GC 5000 BTX; Version 5 11/

112 11.8 Help functions Remote support How to get connected: Clicking onto Remote support will start the AMA Remote Support utility. Then AMA Instruments service engineers can connect to the analyzer via Internet and can help you by remote maintenance: 1. Tell us the ID and 2. the password About Clicking About will inform you about the running software version. This is useful if you have any questions. Operating Manual GC 5000 BTX; Version 5 11/

113 12 Miscellaneous procedures 12.1 Programming and editing values Change of parameters in general 1. Select Menu bar Parameters 2. Click on the input field of the parameter which has to be modified. 3. Enter the new value by keyboard or by clicking the corresponding buttons on the numeric input window. 4. Select Menu bar save as actual values The new parameters are saved as current values in case no errors are detected. (See chapter ). Before the new parameters are accepted as new working parameters, they will be checked automatically by the system. The system indicates an error message in case parameters are not allowed. Change of parameters during program run: Change of time set points In general all parameters can be changed at every time and in every program step. The following points have to be noticed if you need to change parameters when the sample program is running. It is not possible to change the time for an already running program step. In this case the new time value will get active in the next cycle. Example: The program step sampling is running and the value for the sampling time has been changed and saved as current value. Effect: The sampling will end with the old value of the sampling time. But in the next cycle the sampling will get started with the new sampling time. The maximum for each program step is: 59 min 59 sec. The maximum for the cycle time is: 23h 59 min und 59 sec. Change of temperature set points New temperature set points will be accepted immediately and independent from the current program step. Operating Manual GC 5000 BTX; Version 5 11/

114 12.2 Programming GC oven parameters How to display the running temperature program: 1. Select Menu bar Parameters GC oven An initial temperature below + 40 C is not possible. The heating rates have to range between 0 C/min and 25 C/min. Every final temperature has to be equal or higher than its start temperature. No temperature value is allowed to exceed +210 C. Setting a temperature rate to zero means the temperature program will end at this point and the following parameters will be ignored. Operating Manual GC 5000 BTX; Version 5 11/

115 Selection of the parameters for the running temperature program: Initial temperature In this field, the value of the initial temperature has to be selected. It has to be between +40 C and +210 C. Otherwise an error message will occur. Initial time During this time the GC oven temperature is kept on the level of the initial temperature. Heating rate 1 Final temperature 1 In this field the selection of the heating rate for the first phase of the temperature program is possible. It has to range between 0 C/min and +25 C/min. This means the end temperature of the first heating ramp. It is simultaneously the starting temperature for the second phase of the temperature program. Final time 1 temperature Heating rate 2 Final temperature 2 Final time 2 Heating rate 3 Final temp. 3 Final time 3 Total time of GC oven During this time the GC oven temperature is kept on the level of the final temperature 1. This can be the final temperature of the program (heating rate 2 = 0) or the base temperature of the next heating phase. In this field the selection of the heating rate for the second phase of the temperature program is possible. It has to range between 0 C/min and +25 C/min. This means the end temperature of the second heating ramp. It is simultaneously the starting temperature for the third phase of the temperature program. During this time the GC oven temperature is kept on the level of final temperature 2. This can be the final temperature of the program (heating rate 3 = 0) or the base temperature of the next heating phase. In this field the selection of the heating rate for the third and last phase of the temperature program is possible. It has to range between 0 C/min and +25 C/min. This means the end temperature of the third and last heating ramp. During this time the GC oven temperature is kept on the level of final temperature 3. This is the final temperature of the program. In the following step the GC oven is cooled down to the initial temperature. The total time for the GC oven temperature program is the addition of all isotherm and heating times. This value will be updated after pressing the calculate button. Operating Manual GC 5000 BTX; Version 5 11/

116 12.3 Start and stop How to start a program cycle: 1. Start a program cycle by pressing the Start button in the main window. Then a small window pops up: 2. If you click ok, the cycle starts immediately. or 3. If you check Set time for start a new input area pops up: 4. Enter the time for the start in the 24 hours format, i.e. 18 o clock means 6 o clock pm. The analyzer waits until this time and starts the cycle automatically. Operating Manual GC 5000 BTX; Version 5 11/

117 How to stop a running program step: 1. Press the Stop button in the main window, if the program is running and you want to stop it. Then a small window pops up: 2. If you press OK the program stops immediately. or 3. If you select Stop when analysis is completed the analyzer continues completing data acquisition of this chromatogram. One minute later the analyzer stops. Operating Manual GC 5000 BTX; Version 5 11/

118 12.4 Subsequent data processing You can adjust integration parameters and/or retention windows in case a recorded chromatogram have not been integrated properly (as described in the chapters 7.2 and 7.4). Furthermore you can reprocess already acquired chromatograms again. How to process already acquired chromatograms: 1. Use the Chrom Perfect module Data Acquisition which gets automatically started by the GC-5000 controlling software. 2. Select Instrument Control in the context menu on the lower half of the window. In the new window click onto the button Change Download. Then the following window pops up: On the tab Finished Jobs the last recorded chromatograms are listed. 1. Mark the chromatograms which shall be analyzed and click onto the button Create Sequence file from selected entries 2. Save the sequence file under any name. 3. Menu bar Parameters CP Analysis Start CP Analysis and load any chromatogram. Operating Manual GC 5000 BTX; Version 5 11/

119 4. Menu bar Tools Batch process Select Batch Process in the Tools menu and the following window pops up: 5. Check that the radio button of Sequence File is marked and press OK. 6. In the next window select the sequence file which you created before and click onto OK. The next window displays a list of chromatogram files: 7. Press OK and the sequence is automatically worked off and a table with the results (c:\cpdata\gc5000\results.txt) is created. Is the table already present, then the new results are appended to the end of the old file. With menu bar view results table, the results will be displayed as well in the GC 5000 Software. Operating Manual GC 5000 BTX; Version 5 11/

120 Optionally: When you double-click onto the traffic light symbol which appeared in the notification area of the PC, a new window pops up in which you can see the progress of the batch processing: Operating Manual GC 5000 BTX; Version 5 11/

121 13 Maintenance 13.1 Security instructions Warning! Electrical parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Disconnect the GC 5000 from the power supply before starting with maintenance. Warning! The enrichment tube is normally heated to 230 C (up to 300 C). Disregard may result in third-degree-burns. Wait until the tube has cooled down! Caution! There can be a wrong temperature measurement because of different electrical potential. Avoid direct contact between the thermocouples and metal parts. Warning! During the exchange of the rotary valve, the unit has to be switched on as the valve has to be turned. Electrical parts apply hazardous voltage while in use. Only qualified, accredited technicians in the field of electricity are permitted to exchange the rotor. Warning! The valve oven heater is normally heated up to 80 C (max. 150 C). Disregard may result in third-degree-burns. Adjust the valve oven temperature to 40 C and wait until the heater has cooled down to 40 C Operating Manual GC 5000 BTX; Version 5 11/

122 13.2 Maintenance schedule On a preventive maintenance basis we recommend to replace the following components at regular intervals. Maintenance work shall only be done by AMA Instruments or by authorized maintenance personnel, i.e. authorized for maintaining and repairing this kind of systems and electrical circuits in accordance with accepted technical safety standards. Component Back panel fan BTX enrichment tube Fan of the Peltier cooler GC column GC oven motor Inlet filter for MFC Maintenance kit FID (FID jet, sealings) Maintenance kit PID (lamp, centering ring, sealing) Pump Rotor of the rotary valve Yearly x x x x x Every two years x x x x x Operating Manual GC 5000 BTX; Version 5 11/

123 13.3 Maintenance work Exchange the enrichment tube Warning! The enrichment tube is normally heated to 230 C (up to 300 C). Disregard may result in third-degree-burns. Wait until the tube has cooled down! How to remove the old tube and mount the new one: 1. Disconnect the thermocouple plug of the enrichment tube. 2. Close the carrier gas. 3. Remove the PVC cover of the Peltier cooler. 4. Demount the 1/8 nuts on both sides of the enrichment tube and loosen the brass nuts on the ceramic isolators. 5. Remove the four screws and the aluminum top from the Peltier cooler. 6. Take the enrichment tube and the Teflon isolators out of the cooler. 7. Mount the new enrichment tube between the two fittings. 8. Adjust the tube exactly in the center of the cooler and the thermocouple on top of the tube. 9. Tighten the brass nuts on the ceramic isolators. 10. Mount the aluminum top again. 11. Put the PVC cover onto the cooler again. 12. Plug in the thermocouple plug. The new enrichment tube is inserted. Fig. 7: Exploded view of the Peltier cooler of the enrichment tube Operating Manual GC 5000 BTX; Version 5 11/

124 Maintenance of the pump The built-in pump is absolutely maintenance free. If the membrane is abraded (the flow rate will drop dramatically) the complete pump has to be exchanged Exchange the input filter of the MFC To protect the MFC from dust or other small particles a filter is mounted in front of the MFC. Is the filter blocked, it has to be exchanged. Exchange the filter: 1. Loosen the two fittings 2. Pull the filter out of its holder. 3. Put a new filter into the holder 4. Mount the two fittings again. Operating Manual GC 5000 BTX; Version 5 11/

125 Exchange or repair the capillary column Warning! Electrical parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Disconnect the GC 5000 from the power supply before starting to exchange the capillary column. Note The column is fragile. Handle it very carefully and avoid hits while mounting in. If you install an already used column, cut off the first 2 cm of this used column. Cut it only with a suitable cutter (see fig. 8 and description on the next page). How to remove an old column: 1. Switch off the system, unplug the power cable 2. Open the cover. 3. Unlock the opening mechanism of the GC oven cover. 4. Pull the locking knob and draw the cover to the right. 5. Lift up the cover. 6. Loosen the 1/16 nuts at both ends of the capillary column (carefully!). 7. Take out the GC column. 8. Put the nuts and fused silica adapters onto the new column and check the ends of the column whether they are blocked by something. (The fused silica adapters are re-usable a lot of times.) 9. Cut off a short piece of the column, if the ends are not flat. Fig The column has to be pushed through the ferrule for 2-3mm. 11. The nuts have to be tightened until the column is not movable in the ferrule anymore. 12. Mount the GC oven cover in reverse order as described above. The new column is inserted. Operating Manual GC 5000 BTX; Version 5 11/

126 How to prepare and cut a capillary column in the right way: 1. Cut the ends square with none of the polyimide coating projecting beyond the ends. 2. Inspect the ends with a 20X magnifier to make sure the cut is square. 3. In case the end is not square, make a small scratch about 1-inch from the end with a diamond-tipped or ceramic scriber. 4. Therefore hold the column between the thumb and the forefinger, one hand on either side of the scratch. 5. Place the scratch away from you and apply slight pressure with your thumbs. The column should snap easily and cleanly. Note: Avoid making any scratches elsewhere on the column as this can cause your column to break. How to repair a broken column by using a capillary column connector: Universal capillary connectors provide a convenient method to connect a capillary column together without any introduction of dead volume or active sites. 1. One end at a time, firmly press the end of each column into the opening in the capillary column connector. A complete and uniform ring should be visible where the polyimide of the column is in contact with the glass from the fitting. 2. If not, remove the column, re-cut the column, and re-install. A leak-tight connection is formed between the polyimide coating and the fused silica connector. Operating Manual GC 5000 BTX; Version 5 11/

127 Adjust the detector signal Adjust the level of the detector base signal: 1. Turn the trimmer in the upper left corner of the detector amplifier case. 2. Adjust the base signal level after warm up of the system in such a way, that the signal is <100mV when the detector is off and > 100mV when it is on Check the glow plug 1. Pull the FID cover off the detector. 2. Remove the connector with the white cable from the glow plug. 3. Measure the electric resistance between the center pin of the glow plug and the detector case. It should be less than 20Ω but more than 4Ω. 4. If the glow plug is broken, unscrew the glow plug and replace it. 5. Mount the electrical connector again without touching the case of the glow plug. Note There must be a gap between the case of the glow plug and the electric connector. Otherwise you will have a short circuit between both connections of the glow plug and the ignition might not work. Operating Manual GC 5000 BTX; Version 5 11/

128 Check the thermocouples Warning! Electric parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Disconnect the GC 5000 from the power supply before starting to check the thermocouples. Caution! There can be a wrong temperature measurement because of different electrical potential. Avoid direct contact between the thermocouples and metal parts. How to check the status of the thermocouples: 1. Unplug the thermocouple connector 2. Measure the electric resistance between both pins: It should be less than 20Ω. Make sure that there is no connection to the analyzer case. Thermocouple type J color coding: IEC/CEI + black / - white ANSI + white / - red DIN + red / - blue Check the heating units of detector and valve oven Warning! Electrical parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Disconnect the GC 5000 from the power supply before starting to check the heating units of the detector and valve oven. 1. Unplug the heater connector. 2. Measure the electrical resistance between both pins: It should be between 200Ω and 600Ω if it works properly. 3. Exchange the heating unit if the electrical resistance is indefinite high. Operating Manual GC 5000 BTX; Version 5 11/

129 Exchange of the PID lamp Warning! Electrical parts apply voltage while in use. Disregard may result in death, physical injury or damage to property. Shut down and switch off the GC 5000 and disconnect it from the power supply before starting to exchange the PID lamp. Caution! While removing, the PID lamp can fall out of the detector top. Lay a particle-free wipe under the detector top outside of the analyzer and turn the top around and do not hold it downwards. Caution! While removing the PID lamp, the window can get contaminated. This will decrease the UV-intensity and reduce the lifetime of the PID lamp. Therefore do not touch the PID lamp with fingers. Use a particle-free wipe. 1. Remove the top cover. 2. Disconnect the PID power cable (red/blue) from the PCB of the PID top. 3. Remove the two milled screws from the detector top and pull it to the left. Attention: Do not hold the top downwards as the lamp can fall out of the detector top. 4. Lay a particle-free wipe under the detector top outside of the analyzer and turn the top around. The lamp slips out of the exciter coil. 5. Loosen the big PEEK nut on the PID bottom. 6. Pull out the Viton sealing with a forceps and replace it with a new one. 7. Tighten the PEEK nut again. 8. Take the PID top and put the new lamp into the exciter coil without touching the lamp with the fingers. 9. Hold the PID top horizontally with the electric connector on the left side and move it towards the PID bottom until the two brackets reach their leadings. 10. Do not cant the movable part. 11. Mount the two milled screws again. 12. Connect the cable again. The new PID lamp is inserted. Operating Manual GC 5000 BTX; Version 5 11/

130 Clean the PID lamp window 1. Demount the PID as described in Use a particle-free wipe and dry methanol to clean the lamp window. 3. Mount the PID again as described in Exchange the rotor of the rotary valve Warning! During the exchange of the valve the GC 5000 has to be switched on as the valve can be turned. Electrical parts apply hazardous voltage while in use. Only qualified and accredited technicians in the field of electricity are permitted to exchange the rotor. Warning! The valve oven heater is normally heated up to 80 C (max. 150 C). Disregard may result in third-degree-burns. Adjust the valve oven temperature to 40 C and wait until the heater has cooled down to 40 C Fig. 8: Exploded view of the rotary valve Operating Manual GC 5000 BTX; Version 5 11/

131 How to exchange the rotor of the rotary valve: 1. Turn off the carrier gas supply but let the GC 5000 switched on. 2. Remove the cover of the valve oven. 3. Loosen the set screw in the heater of the valve (Caution, hot!) and pull the heater off the valve. 4. Unscrew the entire knurled preload assembly as shown in the figure aside. Note: Do not tamper with the preset socket adjustment screw. 5. Engage the end of the rotor with a pencil-type magnet. 6. After the valve is switched once (Program steps, Enrichment, Sampling) the rotor can be taken out. 7. Put a new rotor in. 8. Take care that the ID letter E on the rotor tab is directed toward port 4 of the valve. (port 4 is marked with an arrow, see fig. aside) 9. Turn the preload assembly into the valve body again by hand just beyond the point where it touches the rotor. 10. Cycle the valve 10 times (Program steps, Enrichment, Sampling respectively Program stopped). 11. Tighten the preload assembly in quarter-turn increments, cycling the valve 10 times after each step. 12. Repeat this step until the preload assembly cannot be tightened anymore by hand. 13. Install the heater again and fix it with the set screw. 14. Mount the valve oven cover. The new rotor is inserted. Operating Manual GC 5000 BTX; Version 5 11/

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