Swan Analytical Instruments AMI INSPECTOR Hydrogen Operator's Manual
AMI INSPECTOR
Hydrogen
Version 6.21 and higher
A-96.250.741 / 050218
Operator’
s Manual
© 2016, SWAN ANALYTISCHE INSTRUMENTE AG, Switzerland, all rights reserved
subject to change without notice.
Customer Support
SWAN and its representatives maintain a fully trained staff of technical specialists
around the world. For any technical question, contact your nearest
SWAN representative, or the manufacturer:
SWAN ANALYTISCHE INSTRUMENTE AG
Studbachstrasse 13
8340 Hinwil
Switzerland
Internet: www.swan.ch
E-mail: support@swan.ch
Document Status
Title:
Monitor AMI INSPECTOR Hydrogen Operator’s Manual
ID:
A-96.250.741
Revision Issue
00 May 2013 First Edition
01 Nov. 2013 New main board, integrated USB interface
02 Jan. 2016 AMI Inspector Version 2-A (with AMIAKKU main-
board) and Firmware version 6.00
AMI INSPECTOR Hydrogen
A-96.250.741 / 050218 1
Table of Contents
1. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1. Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2. General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1. Description of the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2. Instrument Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1. Installation Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2. Connecting Sample Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . 14
3.2.1 Connect the Sample Inlet to the Quick-Lock Coupling . . . . . . . 14
3.2.2 Connect the Sample Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4. Connection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5. Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.2 Alarm Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.3 Relay Contacts 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6. Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. Instrument Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1. Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3. Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4. Changing Parameters and values . . . . . . . . . . . . . . . . . . . . . . . . 26
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1. Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2. Stop of Operation for Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 27
6.3. Maintenance of the Hydrogen Sensor . . . . . . . . . . . . . . . . . . . . . 28
6.3.1 Hydrogen Sensor Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.3 Replace Hydrogen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4. Quality Assurance of the Instrument . . . . . . . . . . . . . . . . . . . . . . 32
2 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
6.4.1 Activate SWAN Quality assurance procedure. . . . . . . . . . . . . . 33
6.4.2 Pre-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4.3 Connect the sample lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4.4 Carry out comparison measurement . . . . . . . . . . . . . . . . . . . . . 36
6.4.5 Completion of the measurement . . . . . . . . . . . . . . . . . . . . . . . . 37
6.5. Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.6. Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.7. Longer Stop of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7. Error List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8. Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1. Messages (Main Menu 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2. Diagnostics (Main Menu 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.3. Maintenance (Main Menu 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.4. Operation (Main Menu 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.5. Installation (Main Menu 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9. Program List and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . 49
1 Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10. Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11. Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
12. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
AMI INSPECTOR Hydrogen
Safety Instructions
A-96.250.741 / 050218 3
AMI INSPECTOR Hydrogen Operator’s Manual
This document describes the main steps for instrument setup, operation and maintenance.
1. Safety Instructions
General The instructions included in this section explain the potential risks
associated with instrument operation and provide important safety
practices designed to minimize these risks.
If you carefully follow the information contained in this section, you
can protect yourself from hazards and create a safer work environment.
More safety instructions are given throughout this manual, at the
respective locations where observation is most important.
Strictly follow all safety instructions in this publication.
Tar get
audience
Operator: Qualified person who uses the equipment
for its intended purpose.
Instrument operation requires thorough knowledge of applications,
instrument functions and software program as well as all applicable
safety rules and regulations.
OM Location The AMI Operator’s Manual shall be kept in proximity of the instru-
ment.
Qualification,
Training
To be qualified for instrument installation and operation, you must:
read and understand the instructions in this manual as well as
the Material Safety Data Sheets.
know the relevant safety rules and regulations.
4 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Safety Instructions
1.1. Warning Notices
The symbols used for safety-related notices have the following significance:
DANGER
Your life or physical wellbeing are in serious danger if such
warnings are ignored.
Follow the prevention instructions carefully.
WARNING
Severe injuries or damage to the equipment can occur if such
warnings are ignored.
Follow the prevention instructions carefully.
CAUTION
Damage to the equipment, minor injury, malfunctions or incorrect process can be the consequence if such warnings are ignored.
Follow the prevention instructions carefully.
Mandatory
Signs
The importance of the mandatory signs in this manual.
Safety goggles
Safety gloves
AMI INSPECTOR Hydrogen
Safety Instructions
A-96.250.741 / 050218 5
Warning Signs The importance of the warning signs in this manual.
Electrical shock hazard
Corrosive
Harmful to health
Flammable
Warning general
Attention general
6 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Safety Instructions
1.2. General Safety Regulations
Legal
Requirements
The user is responsible for proper system operation.
All precautions must be followed to ensure safe operation
of the instrument.
Spare Parts
and
Disposables
Use only official SWAN spare parts and disposables. If other parts
are used during the normal warranty period, the manufacturer’s
warranty is voided.
Modifications Modifications and instrument upgrades shall only be carried out by
an authorized Service Technician. SWAN will not accept responsibility for any claim resulting from unauthorized modification or alteration.
WARNING
Risk of Electrical Shock
If proper operation is no longer possible, the instrument must be
disconnected from all power lines, and measures must be taken
to prevent inadvertent operation.
To prevent from electrical shock, always make sure that the
ground wire is connected.
Service shall be performed by authorized personnel only.
Whenever electronic service is required, disconnect instru-
ment power and power of devices connected to.
–relay 1,
–relay 2,
– alarm relay
WARNING
For safe instrument installation and operation you must read
and understand the instructions in this manual.
WARNING
Only SWAN trained and authorized personnel shall perform the
tasks described in this document.
AMI INSPECTOR Hydrogen
Product Description
A-96.250.741 / 050218 7
2. Product Description
This chapter contains technical data, requirements and performance data.
2.1. Description of the System
The portable AMI INSPECTOR instrument is a complete monitoring
system mounted on a small panel with supporting stand and a rechargeable battery for stand-alone operation (>24h), designed as
an inspection equipment for quality assurance of online process
monitors.
Features General Features of AMI INSPECTORs are:
Battery life after full charge:
– >24h at full load (
use of 3 relays, USB, signal output, logger
)
– >36h at minimum load (use of logger only)
Charging time: approx. 6 hours
Controlled shut-down if battery is empty.
Display of remaining battery life in hours.
For longer battery life the back light of the LC Display is dis-
abled.
Continuous operation using power adapter. The battery
should be discharged at least once a month (normal usage
until the monitor automatically shuts down).
Battery The Li-Ion battery is located in the housing of the AMI transmitter.
See chapter Power Supply, p. 18 regarding power supply and
charging of the battery.
Safety features No data loss after power failure, all data is saved in non-volatile
memory. Over voltage protection of in- and outputs.
Galvanic separation of measuring inputs and signal outputs.
USB interface Built-in USB interface for logger download. Use the USB stick sup-
plied by Swan only (other USB sticks can dramatically reduce battery life).
8 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Product Description
Signal Output One signal output programmable for measured values (freely
scaleable, linear or bilinear) or as continuous control output (control
parameters programmable).
Current loop: 0/4–20 mA
Maximal burden: 510
Relay Two potential-free contacts programmable as limit switches for
measuring values, controllers or timer for system cleaning with automatic hold function.
Maximum load: 100 mA/50 VAC
Alarm Relay One potential free contact.
Alternatively:
Open during normal operation, closed on error and loss of
power.
Closed during normal operation, open on error and loss of
power.
Summary alarm indication for programmable alarm values and instrument faults.
Input For potential-free contact to freeze the measuring value or to inter-
rupt control in automated installations (hold function or remote-off)
Measuring
principle
Hydrogen is measured by an amperometric method. A small voltage, called polarization voltage, is applied between two electrodes.
If a hydrogen molecule hits the positively charged platinum electrode (anode) it will be oxidized. This means that two electrons are
removed under the influence of the positive voltage and the catalytic properties of the platinum. This leaves two (charged) protons and
two electrons behind.
(1) H2 ––> 2 H
+
+ 2 e
-
The two electrons are transported by the polarization voltage
source to the negatively charged silver-silver chloride electrode
(cathode), causing the following reaction:
(2) AgCl + 2 e
-
––> Ag + 2 Cl
-
Finally the two kinds of ions produced will combine into a small
amount of hydrochloric acid:
(3) 2 H+ + 2 Cl
-
––> 2 HCl
If the hydrogen concentration in the sample increases more hydrogen molecules will hit the platinum anode within a given time.
Therefore more electrons will be transported within a given time
which corresponds actually to an increased electrical current. This
current can be measured by the electronics. It is directly proportional to the concentration of hydrogen in the sample. Formula (2) indi-
AMI INSPECTOR Hydrogen
Product Description
A-96.250.741 / 050218 9
cates that in the course of the hydrogen measurement the silver
chloride is reduced to elemental silver. If all silver chloride has been
converted to silver the hydrogen sensor has to be refurbished in the
factory. However there is enough silver chloride provided to keep
the sensor operational during two years under normal conditions.
The actual SWAN hydrogen-sensor design is based on the wellknown Clark principle. Clark-type oxygen sensors have been successfully in use for many years.
Hydrogen sen-
sor schematic
view
A
B
C
D
E
Polarization voltage source
Display
Sensor Body
Sample
Silver cathode
F
G
H
I
J
Electrolyte
Platinum Anode
Temperature sensor
Thin layer of electrolyte
Hydrogen permeable
membrane
25.6 °C
1.24 ppb
A
B
C
D
E
F
G
H
J
I
10 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Product Description
Fluidics The sample flows via sample inlet [E] through the flow regulating
valve [D], where the flow rate can be adjusted. Then the sample
flows into the measuring cell [C] were the hydrogen concentration
of the sample is measured.
The sample leaves the measuring cell via flow sensor [B] through
the sample outlet [F].
A
B
C
Hydrogen sensor
Flow sensor
Measuring cell
D
E
F
Flow regulating valve
Sample inlet
Sample outlet
A
B
C
D
E
F
AMI INSPECTOR Hydrogen
Product Description
A-96.250.741 / 050218 11
2.2. Instrument Overview
A
B
C
D
AMI Transmitter
Hydrogen sensor
Flow cell
Flow sensor
E
F
G
Flow regulating valve
Sample outlet
Sample inlet
A
B
D
C
F
G
E
12 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Product Description
2.3. Technical Data
Power Supply Battery
Use original, supplied power adapter only.
Voltage:
Power consumption:
Charging time:
Battery type:
85–265 VAC, 50/60 Hz
max. 20 VA
6h
Li-Ion
During charging protect from heat impact and keep splash-proof
(not IP66).
Operating time Stand-alone (Battery):
Connected adapter:
> 24h
continuous
Controlled shut-down when battery is empty, remaining time is displayed.
Electronics Aluminium with a protection degree of IP 66 / NEMA 4X
housing Ambient temperature:
Humidity:
Display:
-10 to +50 °C
10–90% rel., non condensing
backlit LCD, 75 x 45 mm
Sample
requirements
Flow rate:
Temperature:
Inlet pressure:
Outlet pressure:
6 to 20 l/h
up to 45 °C
0.2 to 1 bar
pressure free
Flow cell and
connection
Flow cell made of acrylic glass with built-in flow adjustment valve
and digital sample flow meter
Sample inlet:
Sample outlet:
1/4” Swagelok tube adapter
flexible tube 8x 6 mm
Measuring
Range
Range
0.1 to 199 ppb
200 to 800 ppb
0 – 50% saturation
Resolution
0.1 ppb
1 ppb
0.1% Saturation
Accuracy
Reprodu-
cibility
±3 % of measured value or ± 0.5 ppb
±1 % of measured value or ± 0.5 ppb
AMI INSPECTOR Hydrogen
Installation
A-96.250.741 / 050218 13
3. Installation
3.1. Installation Check List
Check
Instrument’s specification must conform to your AC power
ratings. See External power adapter, p. 19.
Check if the battery is fully charged.
Installation
Connect the sample and waste line.
Power-up
Open the flow regulating valve.
Switch on power
Adjust the sample flow to 6–20 l/h.
Instrument
Setup
Program all parameters for external devices (interface,
recorders, etc.)
Program all parameters for instrument operation (limits,
alarms).
Run-in period
Let the instrument run continuously for 1 h.
14 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Installation
3.2. Connecting Sample Inlet and Outlet
3.2.1 Connect the Sample Inlet to the Quick-Lock Coupling
The AMI INSPECTOR Hydrogen is delivered with a quick-lock coupling. To connect the sample line to the AMI INSPECTOR Hydrogen, simply push the nipple into the quick-lock coupling.
A
B
C
D
Flow cell block
Quick-lock coupling
Nipple
Sample outlet
A
B
C
D
AMI INSPECTOR Hydrogen
Installation
A-96.250.741 / 050218 15
3.2.2 Connect the Sample Outlet
Installation 1 Loosen the union nut [B] but do not remove it.
2 Push the FEP tube [A] through the union nut [B] as far as it
reaches the stop of the threaded tube [E].
3 Tighten the union nut 1¾ rotation using an open ended spanner.
Hold Body from turning with a second wrench.
4 Put the FEP Tube into a pressure free drain with sufficient ca-
pacity.
A
B
C
FEP tube 8x 6
Union nut
Compression ferrule
D
E
F
Compression cone
Threaded tube
Tightened connection
ABCD E
F
16 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Installation
3.3. Electrical Connections
WARNING
Always turn off DC power before manipulating electric parts.
Make sure the power specification of the instrument corresponds to the power on site.
Cable
thicknesses
In order to comply with IP66, use the following cable thicknesses
NOTICE: Protect unused cable glands
Wire For Relays: Use max. 1.5 mm2 / AWG 14 stranded wire with
end sleeves.
For Signal Outputs and Input: Use 0.25 mm
2
/ AWG 23
stranded wire with end sleeves.
WARNING
External Voltage
External supplied devices connected to relay 1 or 2 or to the
alarm relay can cause electrical shocks.
Make sure that the devices connected to the following con-
tacts are disconnected from the power before continuing the
installation.
–relay 1
–relay 2
– alarm relay
A
B
PG 9 cable gland: cable Ø
outer
4–8 mm
PG 7 cable gland: cable Ø
outer
3–6.5 mm
ON
OFF
AB
AMI INSPECTOR Hydrogen
Installation
A-96.250.741 / 050218 17
3.4. Connection Diagram
CAUTION
Use only the terminals shown in this diagram, and only for the
mentioned purpose. Use of any other terminals will cause short
circuits with possible corresponding consequences to material
and personnel.
18 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Installation
3.4.1 Power Supply
Contrary to all other Swan online process monitors the AMI INSPECTOR transmitter is supplied with power by battery only. The
rechargeable battery (Li-Ion) enables a stand-alone operation for at
least 24 hours.
WARNING
Do not provide power directly to the transmitter as this will destroy the motherboard. All AMI INSPECTOR transmitters are
supplied with power by battery only.
Charging Use the original supplied power adapter to charge AMI INSPEC-
TOR only. Charging time: approx 6h.
Fully charged a stand-alone operating time of at least 24h is guar-
anteed:
>24h at full load (use of 3 relays, USB, signal outputs, logger)
>36h at minimal load (use of logger only)
In case that the battery is discharged completely the firmware will
automatically shut down.
Switch Power
ON - OFF
Switch the instrument ON or OFF using the toggle switch on the
transmitter.
Continuous
operation
For continuous operation use the power adapter as well.
CAUTION
If the AMI powers ON and then immediately shuts OFF, the
battery is empty. Do not hold the toggle switch in ON position,
as this can damage the battery.
CAUTION
During charging protect from heat impact and keep splash-
proof (plug of power adapter is not IP66).
Do not supply external devices, e.g. pumps, magnetic valves
or any other current consumers with AMI INSPECTOR
CAUTION
Use the original supplied power adapter to charge AMI IN-
SPECTOR only. Use of any other power adapter can damage
the battery or cause malfunction
AMI INSPECTOR Hydrogen
Installation
A-96.250.741 / 050218 19
External
power adapter
Universal input range
85 - 265 VAC
Continuous short circuit protection
Over voltage protection
LED indicator for power on
2-pin AC inlet (IEC 320-C8) for
detachable country-specific power
cord
Power cords Two different power cords are supplied:
Power cord with type C plug (Europlug)
Power cord with type A plug (NEMA-1)
If a different plug type is needed, please purchase a suitable power
cord from your local supplier.
NOTICE: Do not use any plug adapters.
Dimensions
Unit: mm
20 A-96.250.741 / 050218
AMI INSPECTOR Hydrogen
Installation
3.5. Relay Contacts
Programming of the relay contacts see 5.3 Relay Contacts, p. 58
3.5.1 Input
NOTICE: Use only potential-free (dry) contacts.
Terminals 13/ 14
If signal output is set to hold, measurement is interrupted if input is
active.
For programming see menu 5.3.4, p. 64.
3.5.2 Alarm Relay
NOTICE: For resistive loads only; do not use with capacitive or
inductive loads. Max. load 1 A / 250 VAC
Alarm output for system errors.
Error codes see Error List, p. 40
Programming see menu 5.3.1, p. 58
NOTICE: With certain alarms and certain settings of the AMI
transmitter the alarm relay does not switch. The error, however,
is shown on the display.
1) usual use
Ter min als Description Relay connection
NC
1)
Normally
Closed
5/4 Active (opened) during normal
operation.
Inactive (closed) on error and
loss of power.
NO
Normally
Open
5/ 3 Active (closed) during normal
operation.
Inactive (opened) on error and
loss of power.
4
3
5
0V
1)
4
3
5
0V
AMI INSPECTOR Hydrogen
Installation
A-96.250.741 / 050218 21
3.5.3 Relay Contacts 1 and 2
NOTICE: For resistive loads only; do not use with capacitive or
inductive loads. Rated load 100 mA / 50 VAC
For programming see Menu Installation 5.3.2 and 5.3.3, p. 60
3.6. Signal Output
The signal output 0/4–20 mA PCB is plugged onto the USB interface PCB.
NOTICE: Max. burden 510 Ω.
Terminals 16 (+) and 15 (-).
For programming see menu 5.2 Signal Outputs, p. 54.
Terminals Description
Relay connection
NO
Normally
Open
6/ 7: Relay 1
8/ 9: Relay 2
Inactive (opened) during normal
operation and loss of power.
Active (closed) when a programmed function is executed.
A
B
Signal output 0/4–20 mA PCB
USB interface
A B
6/8
0V
7/9
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