Swann AMI Hydrogen QED Operator's Manual

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Page 1

AMI Hydrogen QED

Version 6.22 and higher

A-96.250.791 / 040219

Operator’

s Manual

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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:

AMI Hydrogen QED Operator’s Manual

ID:

A-96.250.791

Revision Issue

00 April 2014 First Edition

01 July 2017 New mainboard V2.5, firmware V6.20

Page 3

AMI Hydrogen QED

A-96.250.791 / 040219 1

Table of Contents

1. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1. Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2. General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1. Description of the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3. Instrument Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.1. Installation Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.2. Mounting of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.3. Connecting Sample Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . 15

3.3.1 Swagelok Fitting Stainless Steel at Sample Inlet . . . . . . . . . . . 15

3.3.2 Sample Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5. Connection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.6. Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.7. Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.7.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.7.2 Alarm Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.7.3 Relay Contacts 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.8. Signal Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.8.1 Signal output 1 and 2 (current outputs) . . . . . . . . . . . . . . . . . . . 24

3.9. Interface Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.9.1 Signal Output 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.9.2 Profibus, Modbus Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.9.3 HART Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.9.4 USB Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4. Instrument Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1. Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.2. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.3. Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.4. Changing Parameters and Values . . . . . . . . . . . . . . . . . . . . . . . . 32

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AMI Hydrogen QED

6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.1. Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.2. Stop of Operation for Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 33

6.3. Maintenance of the Hydrogen Sensor . . . . . . . . . . . . . . . . . . . . . 34

6.3.1 Hydrogen Sensor Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.3.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.3.3 Faraday Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.3.4 Replace Hydrogen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.4 Maintenance of the Faraday Electrode . . . . . . . . . . . . . . . . . . . . . 38

6.5. Quality Assurance of the Instrument. . . . . . . . . . . . . . . . . . . . . . . 40

6.5.1 Activate SWAN Quality assurance procedure. . . . . . . . . . . . . . 41

6.5.2 Pre-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.5.3 Connect the sample lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.5.4 Carry out comparison measurement . . . . . . . . . . . . . . . . . . . . . 44

6.5.5 Completion of the measurement . . . . . . . . . . . . . . . . . . . . . . . . 45

6.6. Longer Stop of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.1. Error List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.2. Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8. Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.1. Messages (Main Menu 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.2. Diagnostics (Main Menu 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.3. Maintenance (Main Menu 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.4. Operation (Main Menu 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

8.5. Installation (Main Menu 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

9. Program List and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . 55

1 Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

10. Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

11. Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

12. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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AMI Hydrogen QED

Safety Instructions

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AMI Hydrogen QED 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.

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AMI Hydrogen QED

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

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AMI Hydrogen QED

Safety Instructions

A-96.250.791 / 040219 5

Warning Signs The importance of the warning signs in this manual.

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.

Electrical shock hazard

Corrosive

Harmful to health

Flammable

Warning general

Attention general

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AMI Hydrogen QED

Safety Instructions

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.

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AMI Hydrogen QED

Product Description

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2. Product Description

This chapter contains technical data, requirements and performance data.

2.1. Description of the System

Application

Range

The AMI Hydrogen QED is a monitor for continuous measurement of dissolved hydrogen in water.

Signal

Outputs

Two signal outputs programmable for measured values (freely scalable, linear or bilinear) or as continuous control output (control parameters programmable).

Current loop: 0/4 –20 mA Maximal burden: 510 Ω Third signal output available as an option. The third signal output

can be operated as a current source or as a current sink (selectable via switch).

Relay Two potential-free contacts programmable as limit switches for

measuring values, controllers or timer for system cleaning with automatic hold function. Both contacts can be used as normally open or normally closed.

Maximum load: 1 A/250 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)

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.

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AMI Hydrogen QED

Product Description

Communica-

tion Interface

(optional)

 USB Interface for logger download  Third signal output (can be used in parallel to the USB interface)  RS485 with Fieldbus protocol Modbus or Profibus DP  HART interface

Faraday

Verification

The Faraday verification is used to check the sensor periodically. The intervals can be freely programmed in the menu operation.

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 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) indicates 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 hydrogen sensors have been successfully in use for many years.

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AMI Hydrogen QED

Product Description

A-96.250.791 / 040219 9

Hydrogen

sensor

schematic

view

A B C D E F

Polarization voltage source Display Sensor body Sample Cathode Electrolyte

G H I J

Anode Temperature sensor Thin layer of electrolyte Hydrogen permeable membrane

25.6 °C

1.24 ppb

E F G

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AMI Hydrogen QED

Product Description

Fluidics Swansensor Hydrogen combined with QV-flow PMMA OTG flow

cell [A]. The sample flows via sample inlet [H] through the flow regulating valve [E], where the flow rate can be adjusted. Then the sample flows through the Faraday electrode [D] into the measuring cell were the hydrogen concentration of the sample is measured.

The sample leaves the measuring cell via flow sensor [B] through the sample outlet [F] and flows into the drain funnel [G].

A B C D

Flow cell Flow sensor Swansensor hydrogen Faraday electrode

E F G H

Flow regulating valve Sample outlet Drain funnel Sample inlet

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AMI Hydrogen QED

Product Description

A-96.250.791 / 040219 11

2.2. Technical Data

Power Supply Voltage:

Power consumption:

100–240 VAC (± 10%) 50/60 Hz (± 5%) or 24 VDC (± 10%) max. 30 VA

Electronics Aluminium with a protection degree of IP 66 / NEMA 4X

housing Ambient temperature:

Limit range of operation: Storage and transport: Humidity: Display:

-10 to +50 °C

-25 to +65 °C

-30 to +85 °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

0.01–9.99 ppb

10.0–99.9 100–800 ppb 0–50% saturation

Resolution

0.01 ppb

0.1 ppb 1 ppb

0.1% Saturation

Accuracy

Reprodu-

cibility

±5% of measured value or ± 0.5 ppb ±1% of measured value or ± 0.5 ppb

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AMI Hydrogen QED

Product Description

Dimensions Panel:

Mounting hole distance Screws: Weight:

280x850x150 mm 254x 824 8 mm

12.0 kg

Exit Enter

AMI Hydrogen

850 mm / 33½”

13 mm / ½”

4 x dia. 10 mm /

”

254 mm/ 10”

280 mm/ 11”

824 mm / 32

”

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AMI Hydrogen QED

Product Description

A-96.250.791 / 040219 13

2.3. Instrument Overview

A B C D E F

Panel AMI Transmitter Sample outlet Flow cell Flow sensor Hydrogen sensor

G H I J K

Faraday control Faraday electrode Flow regulating valve Drain funnel Sample inlet

E F

G H

I J

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AMI Hydrogen QED

Installation

3. Installation

3.1. Installation Check List

3.2. Mounting of Instrument Panel

The first part of this chapter describes the preparing and placing of the system for use.

 The instrument must only be installed by trained personnel.  Mount the instrument in vertical position.  For ease of operation mount it so that the display is at eye

level.

 For the installation a kit containing the following installation

material is available: – 4 Screws 8x 60 mm – 4 Dowels – 4 Washers 8.4/ 24 mm

Mounting re-

quirements

The instrument is only intended for indoor installation. For dimensions see Dimensions, p. 12

Check

 Instrument’s specification must conform to the National

Electrical Code, all state and local codes, and all plant codes and standards for electrical equipment.

Installation

 Connect the sample and waste line.

Electrical Wiring

Do not switch on the Instrument until all electrical connections are made.

 Connect all external devices like limit switches, current loops

and pumps.

 Connect power cord, see Electrical Connections, p. 17.

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.

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AMI Hydrogen QED

Installation

A-96.250.791 / 040219 15

3.3. Connecting Sample Inlet and Outlet

3.3.1 Swagelok Fitting Stainless Steel at Sample Inlet

Preparation Cut the tube to length and deburr it. The tube must be straight and

free from blemishes for approximately 1,5 x tube diameter from the end. Lubrication with lubricating oil, MoS2, Teflon etc. is recommended for the assembly and reassembly of bigger sized unions (thread, compression cone).

Installation 1 Insert the compression ferrule [C] and the compression

cone [D] into the union nut [B].

2 Screw on the union nut onto the body, do not tighten it.

3 Push the stainless steel pipe through the union nut as far as it

reaches the stop of the body.

4 Mark the union nut at 6 o’clock position.

5 While holding the fitting body steady, tighten the nut union 1¼

rotation using an open ended spanner.

A B C

Stainless steel tube Union nut Compression ferrule

D E F

Compression cone Body Tightened connection

ABCDE

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AMI Hydrogen QED

Installation

3.3.2 Sample Outlet

1/2” tube at waste funnel.

Connect the 1/2” tube [C] to the hose nozzle [B] and place it into a pressure free drain.

A B C

Waste funnel Hose nozzle 1/2” tube

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AMI Hydrogen QED

Installation

A-96.250.791 / 040219 17

3.4. Electrical Connections

WARNING

Risk of electrical shock.

Do not perform any work on electrical components if the transmitter is switched on. Failure to follow safety instructions could result in serious injury or death.

 Always turn off power before manipulating electric parts.  Grounding requirements: Only operate the instrument from

an power outlet which has a ground connection.

 Make sure the power specification of the instrument corre-

sponds 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 power and relays: Use max. 1.5 mm

/ AWG 14 stranded

wire with end sleeves.

 For signal outputs and input: Use 0.25 mm

/ AWG 23

stranded wire with end sleeves.

A B C

PG 11 cable gland: cable Ø

outer

5–10 mm

PG 7 cable gland: cable Ø

outer

3–6.5 mm

PG 9 cable gland: cable Ø

outer

4–8 mm

ABC

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AMI Hydrogen QED

Installation

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 resuming installation.

–relay 1 –relay 2 – alarm relay

WARNING

To prevent from electrical shock, do not connect the instrument to the power unless the ground wire (PE) is connected.

 Do not connect unless specifically instructed to do so.

WARNING

The mains of the AMI Transmitter must be secured by a main switch and appropriate fuse or circuit breaker.

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AMI Hydrogen QED

Installation

A-96.250.791 / 040219 19

3.5. 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.

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AMI Hydrogen QED

Installation

3.6. Power Supply

WARNING

Electrical shock hazard

Installation and maintenance of electrical parts must be performed by professionals.

 Always turn off power before manipulating electric parts.

NOTICE: The protective earth wire (ground) has to be connected to the grounding terminal.

Installation

requirements

The installation must meet the following requirements.

 Mains fuse 1.6 AT  Mains cable to comply with standards IEC 60227 or IEC

60245; flammable rating FV1

 Mains equipped with an external switch or circuit-breaker

– near the instrument – easily accessible to the operator – marked as interrupter for AMI Hydrogen QED

A B C D

Power supply connector Neutral conductor, Terminal 2 Phase conductor, Terminal 1 Protective earth PE

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AMI Hydrogen QED

Installation

A-96.250.791 / 040219 21

3.7. Relay Contacts

Programming of the relay contacts see 5.3 Relay Contacts, p. 65.

3.7.1 Input

NOTICE: Use only potential-free (dry) contacts. The total resistance (sum of cable resistance and resistance of the relay contact) must be less than 50 Ω.

Terminals 16/42 If signal output is set to hold, measurement is interrupted if input is

active. For programming see menu 5.3.4, p. 71.

3.7.2 Alarm Relay

NOTICE: Max. load1 A T / 250 VAC

Alarm output for system errors. Error codes see Troubleshooting, p. 46 Programming see menu 5.3.1, p. 65

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

Terminals Description Relay connection

Normally Closed

10/11 Active (opened) during normal

operation. Inactive (closed) on error and loss of power.

Normally Open

12/11 Active (closed) during normal

operation. Inactive (opened) on error and loss of power.

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AMI Hydrogen QED

Installation

3.7.3 Relay Contacts 1 and 2

NOTICE: Rated load 1 AT / 250 VAC

Relay 1 and 2 can be configured as normally open or as normally closed. Standard for both relays is normally open. To configure a Relay as normally closed, set the jumper in the upper position.

NOTICE: Some error codes and the instrument status may influence the status of the relays described below.

For programming see Menu Installation 5.3.2 and 5.3. 3, p. 67

Relay config. Terminals

Jumper pos. Description Relay configuration

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.

Normally Closed

6/7: Relay 1 8/9: Relay 2

Inactive (closed) during normal operation and loss of power. Active (opened) when a programmed function is executed.

ABJumper set as normally open (standard setting)

Jumper set as normally closed

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AMI Hydrogen QED

Installation

A-96.250.791 / 040219 23

CAUTION

Risk of damage of the relays in the AMI transmitter due to heavy inductive load.

Heavy inductive or directly controlled loads (solenoid valves, dosing pumps) may destroy the relay contacts.

 To switch inductive loads > 0.1 A use an AMI relay box avail-

able as an option or suitable external power relays.

Inductive load Small inductive loads (max 0.1 A) as for example the coil of a pow-

er relay can be switched directly. To avoid noise voltage in the AMI transmitter it is mandatory to connect a snubber circuit in parallel to the load.

Resistive load Resistive loads (max. 1 A) and control signals for PLC, impulse

pumps and so on can be connected without further measures

Actuators Actuators, like motor valves, are using both relays: One relay con-

tact is used for opening, the other for closing the valve, i.e. with the 2 relay contacts available, only one motor valve can be controlled. Motors with loads bigger than 0.1 A must be controlled via external power relays or an AMI relay box.

A B C D E

AC or DC power supply AMI Transmitter AMI Relay box Snubber Power relay coil

A B C

AMI transmitter PLC or controlled pulse pump Logic

A B C

AC or DC power supply AMI transmitter Actuator

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AMI Hydrogen QED

Installation

3.8. Signal Outputs

3.8.1 Signal output 1 and 2 (current outputs)

NOTICE: Max. burden 510 Ω. If signals are sent to two different receivers, use signal isolator (loop isolator).

Signal output 1: Terminals 14 (+) and 13 (-) Signal output 2: Terminals 15 (+) and 13 (-) Programming see menu 5.2 Signal Outputs, p. 61

3.9. Interface Options

The slot for interfaces can be used to expand the functionality of the AMI instrument with either:

 Third signal output  a Profibus or Modbus connection  a HART connection  an USB interface

A B C D

AMI transmitter Slot for interfaces Frontend PCB Screw terminals

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AMI Hydrogen QED

Installation

A-96.250.791 / 040219 25

3.9.1 Signal Output 3

Terminals 38 (+) and 37 (-). Requires the additional board for the third signal output 0/4– 20 mA.

The third signal output can be operated as a current source or as a current sink (switchable via switch [A]). For detailed information see the corresponding installation instruction.

NOTICE: Max. burden 510 Ω.

Third signal output 0/4 - 20 mA PCB

3.9.2 Profibus, Modbus Interface

Terminal 37 PB, Terminal 38 PA To connect several instruments by means of a network or to config-

ure a PROFIBUS DP connection, consult the PROFIBUS manual. Use appropriate network cable.

NOTICE: The switch must be ON, if only one instrument is installed, or on the last instrument in the bus.

Profibus, Modbus Interface PCB (RS 485)

A Operating mode selector switch

A On - OFF switch

OFF

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AMI Hydrogen QED

Installation

3.9.3 HART Interface

Terminals 38 (+) and 37 (-). The HART interface PCB allows for communication via the HART

protocol. For detailed information, consult the HART manual.

HART Interface PCB

3.9.4 USB Interface

The USB Interface is used to store logger data and for firmware upload. For detailed information see the corresponding installation instruction.

The optional third signal output 0/4 – 20 mA PCB [B] can be plugged onto the USB interface and used in parallel.

USB Interface

A USB interface PCB B Third signal output 0/4 - 20 mA PCB

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AMI Hydrogen QED

Instrument Setup

A-96.250.791 / 040219 27

4. Instrument Setup

Establish

sample flow

1 Open the flow regulating valve [A].

2 Switch on the instrument.

3 The following start-up sequence lasts 8 min, during this time the

instrument is on hold.

4 Adjust the sample flow to 6– 20 l/h. The actual flow is shown on

the transmitter display.

HOLD

25.1 °C

0.0 l/h

15:20:18

07:18

Start-up

Sequence

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AMI Hydrogen QED

Instrument Setup

4.1. Programming

Sensor

parameters

Check the sensor parameters in menu <Installation>\ <Sensors>\<Sensor parameters>.

The sensor characteristics are printed on the label of each sensor.

The following parameters are required:  I

(saturation current)

 p (air pressure)

External

devices

Program all parameters for external devices (interface, recorders, etc.)

Limits, alarms Program all parameters for instrument operation (limits, alarms).

See Program List and Explanations, p. 55.

SwanSensor Hydrogen

A-87.260.001 Is: 3.025 µA

xxxxxxx p: 953 hPa

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AMI Hydrogen QED

Operation

A-96.250.791 / 040219 29

5. Operation

5.1. Keys

Program

Access, Exit

Sensor

Maintenance

An automatic sensor regeneration is carried out at configurable intervals and takes 2 minutes. During this time the signal outputs are set to hold.

A to exit a menu or command (rejecting any changes)

to move back to the previous menu level

B to move DOWN in a menu list and to decrease digits

C to move UP in a menu list and to increase digits

D to open a selected sub-menu

to accept an entry

Exit Enter

BCDA

25.4°C

RUN

9 l/h

14:10:45

1.05 ppb

Installation

Operation

Diagnostics

Messages

Maintenance

Main Menu

Enter

Exit

Sensor

Maintenance

HOLD

25.1 °C

0.0 l/h

15:20:18

01:45

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Operation

5.2. Display

Relay status, symbols

A RUN normal operation

HOLD input closed or cal delay: Instrument on hold (shows

status of signal outputs).

OFF input closed: control/limit is interrupted (shows status

of signal outputs).

B ERROR Error

Fatal Error

C Keys locked, transmitter control via Profibus

D Time

E Process values

F Sample temperature

G Sample flow in l/ h

H Relay status

upper/lower limit not yet reached upper/lower limit reached control upw./downw. no action

control upw./downw. active, dark bar indicates control intensity

motor valve closed motor valve: open, dark bar indicates approx. position timer timer: timing active (hand rotating)

RUN

23 °C

23 l/h

15:20:18

ppm

1.05

AB CD

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AMI Hydrogen QED

Operation

A-96.250.791 / 040219 31

5.3. Software Structure

Menu Messages 1 Reveals pending errors as well as an event history

(time and state of events that have occurred at an earlier point of time). It contains user relevant data.

Menu Diagnostics 2 Provides user relevant instrument and sample data.

Menu Maintenance 3 For instrument calibration, relay and signal output

simulation, and to set the instrument time. It is used by the service personnel.

Menu Operation 4 User relevant parameters that might need to be

modified during daily routine. Normally password protected and used by the process-operator.

Subset of menu 5 - Installation, but process-related.

Menu Installation 5 For initial instrument set up by SWAN authorized

person, to set all instrument parameters. Can be protected by means of password.

Messages

Operation

Maintenance

Diagnostics

Main Menu

Installation

1.1

Pending Errors

Messages

Maintenance List Message List

2.1

Interface

I/O State

Sample

Identification Sensors

Diagnostics

3.1

Calibration

Maintenance

Set Time 23.09.06 16:30:00

Simulation

Service

4.1

Logger

Relay Contacts

Sensors

Operation

5.1

Interface

Miscellaneous

Relay Contacts

Sensors Signal Outputs

Installation

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32 A-96.250.791 / 040219

AMI Hydrogen QED

Operation

5.4. Changing Parameters and Values

Changing

parameters

The following example shows how to change the logger interval:

Changing

values

1 Select the parameter you want to

change.

2 Press [Enter].

3 Press [ ] or [ ] key to

highlight the required parameter.

4 Press [Enter] to confirm the selec-

tion or [Exit] to keep the previous parameter).



The selected parameter is highlighted (but not saved yet).

5 Press [Exit].



Yes is highlighted.

6 Press [Enter] to save the new pa-

rameter.



The system reboots, the new parameter is set.

5.1.2

Sensors

Sensor type FOME

Temperature NT5K Standards

Disinf. Free chlorine

4.4.1

Logger

Log interval 30 min

Clear logger no

4.1.3

Logger

Clear logger no

Log interval 30min

1 Hour

Interval.

5 min

30 min

10 min

4.1.3

Logger

Log interval 10 min

Clear logger no

4.1.3

Logger

Log interval Clear logger no

Save ?

Yes

1 Select the value you want to

change.

2 Press [Enter].

3 Set required value with [ ] or

[] key.

4 Press [Enter] to confirm the new

value.

5 Press [Exit].



Yes is highlighted.

6 Press [Enter] to save the new val-

ue.

5.3.1.1.1

Alarm High 10.00 ppb

Alarm Hydrogen

Alarm Low 2.00 ppb Hysteresis 0.10 ppb Delay 5 Sec

5.3.1.1.1

Alarm Hydrogen

Alarm Low 2.00 ppb Hysteresis 0.10 ppb Delay 5 Sec

Alarm High 8.00 ppb

Page 35

AMI Hydrogen QED

Maintenance

A-96.250.791 / 040219 33

6. Maintenance

6.1. Maintenance Table

6.2. Stop of Operation for Maintenance

1 Shut off power of the instrument.

2 Stop sample flow by closing the flow regulating valve.

If required

 Perform a calibration.

Two years or if required

 Send the sensor to Swan for revision.  After installation of the revised sensor, program saturation

current and air pressure (5.1.3.1, p. 60 and 5.1.3.2, p. 60) as indicated on the sensor label.

To avoid a longer interruption of the measuring operation, a second hydrogen sensor can be purchased. The two sensors can then be used alternately. If two sensors are available, the following procedure is recommended:

 Send the replacement sensor to Swan for revision shortly

before replacement.

 After installing the revised sensor, store the unused sensor

in its original packaging in a cold, dry and dark place.

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Maintenance

6.3. Maintenance of the Hydrogen Sensor

6.3.1 Hydrogen Sensor Handling

 Never attempt to open the hydrogen sensor.  Always store the sensor in water or in the wet flow cell.  Always keep the sensor connected to the AMI transmitter.  Always keep the sensor polarized. Without polarization the

sensor suffers a loss of sensitivity. The AMI Hydrogen QED has a buffered polarization source which will keep the hydrogen sensor polarized for some days, even if the AMI Hydrogen QED is switched off. However, it is a good idea to keep the AMI running all the time. The AMI Hydrogen QED should be connected to the power supply and switched on even if it is not in use.

 During calibration, do not expose the sensor to 100 % hydro-

gen for more than 6 minutes. Otherwise the extremely dry gas might dry out the capillary layer of electrolyte between platinum anode and plastic membrane, which makes the sensor response unstable.

 The hydrogen molecule is very small and migrates into al-

most any material including electrolyte, plastics and even metals and will remain there for some time. After a calibration it may take a few hours until the residual current of the sensor has dropped enough to measure very low levels of hydrogen again.

 The hydrogen sensor usually shows a small positive offset,

which means there is a small positive value in air (without hydrogen, normally below one ppb). This value can be set to zero: <Installation > Sensors > Miscellaneous > Offset. Use with care!

6.3.2 Calibration

The hydrogen sensor of the AMI Hydrogen QED is calibrated with pure hydrogen. To perform a calibration proceed as follows:

NOTICE: Do not expose the sensor to 100% hydrogen for more than 6 minutes.

1 Stop the sample flow at the main tap.

2 Navigate to menu <Maintenance> / <Calibration>.

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AMI Hydrogen QED

Maintenance

A-96.250.791 / 040219 35

3 Press [Enter] to start the calibration and follow the dialog on the

display.

If the calibration fails again, the hydrogen sensor has to replaced by a new one.

4 Unscrew and remove the thread-

ed sleeve [A].

5 Remove the hydrogen sensor [B]

from the flow cell.

6 Dry the sensor membrane and the

flow cell with a soft paper tissue.

7 Flush the flow cell with hydrogen.

8 Stop hydrogen flow and dry the

flow cell.

9 Re-insert the hydrogen sensor into

the flow cell.



Make sure that the sensor

membrane is dry.

10 Start the hydrogen flow.

11 Press [Enter] to start the calibra-

tion measurement.

The saturation should reach 100%, the saturation current should be about

2.0 A to 4.5 A. If the measuring values are not stable during the measuring period, the calibration will be

discarded.

If this is the case, check and if necessary correct your measurement arrangement and try again.

If the calibration was successful press [Enter] to save.

3.1.5

Calibration

Close regulating valve

to turn off sample flow.

<Enter> to continue

3.1.5

Calibration

Take sensor out of

flow cell and dry

membrane and sensor

<Enter> to continue

3.1.5

Calibration

Connect flow cell to a

source of hydrogen and

Dry flow cell inside.

flush with hydrogen.

<Enter> to continue

3.1.5

Calibration

Remount sensor and let

hydrogen stream through

value is accepted.

flow cell gently until

<Enter> to continue

3.1.1

Calibration

Saturation xx.x% Sat. Current x.xx

A

Progress

3.1.1

Calibration

Saturation xx.x % Sat. Current x.xx

A

<Enter> to save

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AMI Hydrogen QED

Maintenance

6.3.3 Faraday Verification

The Faraday verification works only for hydrogen concentrations below 40–50 ppb. If automatic Faraday verification is enabled, a periodic check of the system is performed. A manual verification can be started for test purposes.

Automatic

verification

Per default the instrument performs an automatic Faraday verification every 3 hours. To change the settings for automatic verification navigate to menu <Operation>/<Faraday Parameter>, see menu

4.1.3, p. 58 for details.

Possible settings are:

 off  interval  daily  weekly

Manual

verification

To start a manual verification:

1 Navigate to menu 3.2.2 <Maintenance>/<Service>/<Faraday

Verification>.

Results are saved in the Verification history menu 2.2.1.5

If the Faraday efficiency is below 50%, message E018 is displayed and the Faraday electrode needs to be cleaned, see Maintenance

of the Faraday Electrode, p. 38.

2 Press [Enter] to start the Faraday

Verification.



The verification then starts

immediately.

3 Press [Enter] to confirm the Fara-

day Verification.

3.3

Progress

Faraday Verification

<Enter> to stop

Current Value 1.62 ppb Faraday Conc.

12.85 ppb

3.3

Progress

Faraday Verification

Done

Efficiency 91.5 % Faraday Conc. 12.85 ppb

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AMI Hydrogen QED

Maintenance

A-96.250.791 / 040219 37

6.3.4 Replace Hydrogen Sensor

To replace the hydrogen sensor proceed as follows:

Remove the

old sensor

1 Switch off the AMI Hydrogen QED.

2 Close the flow regulating valve [D].

3 Unscrew and remove the threaded sleeve [A] from the flow cell.

4 Remove the hydrogen sensor [C] from the flow cell.

5 Unscrew and remove the sensor connector [B] from the hydro-

gen sensor.

Install the new

sensor

1 Screw the connector onto the hydrogen sensor and tighten it.

2 Put the hydrogen sensor into the flow cell.

3 Screw the threaded sleeve into the thread of the flow cell to fix

the hydrogen sensor.

4 Open the flow regulating valve and adjust the sample flow to

6–20 l/h.

5 Switch on the AMI Inspector Hydrogen.

6 Let the new sensor run in for at least 1h.

A B C D

Threaded sleeve Sensor connector Hydrogen sensor Flow regulating valve

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AMI Hydrogen QED

Maintenance

6.4 Maintenance of the Faraday Electrode

1 Switch off the instrument and close the flow regulating valve.

2 Open the Faraday control unit.

3 Disconnect and remove the cable from the Faraday control unit.

4 Unscrew and remove the fixing sleeve (A).

5 Remove the Faraday electrode from the flow cell, do not pull on

the cable.

6 Remove the washer (C) and the o-ring [D] from the electrode

body (B).

7 Unscrew the electrode tip containing the hollow electrode (G).

A B C D E F G

Fixing sleeve Electrode body Washer O-ring Inner electrode O-ring Hollow electrode

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AMI Hydrogen QED

Maintenance

A-96.250.791 / 040219 39

8 Clean the inner electrode (E) with a tissue and the hollow elec-

trode with a pipe cleaner.



The electrode surfaces should be shining metallic after

cleaning. If necessary, use a polishing detergent or a small amount of toothpaste.

9 Rinse all parts well with water.

10 Replace the O-ring and the washer if necessary.

11 Screw the hollow electrode finger-tight onto the electrode body.

12 Insert the faraday electrode into flow cell.

13 Tighten fixing sleeve firmly.

14 Feed the electrode cable through the cable gland of the faraday

control unit.

15 Connect the electrode cable to terminal 5 (green) and terminal 6

(white).

16 Switch the instrument on.

17 Open the flow regulating valve and adjust the sample flow be-

tween 6 and 20 l/ h.

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AMI Hydrogen QED

Maintenance

6.5. Quality Assurance of the Instrument

Every SWAN on-line instrument is equipped with integrated, autonomous quality assurance functions to survey the plausibility of each measurement. For the AMI Hydrogen QED these are:

 continuous monitoring of sample flow  continuous monitoring of the temperature inside the transmit-

ter case

 periodic accuracy test with ultra high precision resistors

Further a manual, menu driven inspection procedure can be carried out using a certified reference instrument. The AMI Inspector is connected to the same sample point and provides the reference value. After enabling the quality assurance procedure by defining the quality assurance level, the instrument reminds the user periodically to run the procedure and results are stored in a history for review.

Quality

assurance

level

Central feature of the quality assurance function is the assignment of the monitored process to a Quality assurance level.

There are three predefined levels plus a user level. Hereby the inspection interval, the deviation limits of temperature and measuring result between the inspection equipment and the monitoring instrument are defined.

 Level 1: Trend; Measurement used as an additional informa-

tion to follow the process indicating trends.

 Level 2: Standard; Monitoring of several parameters of a pro-

cess (e.g. hydrogen, saturation). In case of instrument failure, other parameters can be used for process monitoring.

 Level 3: Crucial; Monitoring of critical processes, value is

used for control of another part or subsystem (valve, dosing unit, etc.).

Additional level:

 Quality level 4: User; User defined inspection interval, maxi-

mal deviation of temperature and measuring result.

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AMI Hydrogen QED

Maintenance

A-96.250.791 / 040219 41

Procedure The standard workflow contains following procedures:

1 Activate SWAN Quality assurance procedure

2 Pre-test

3 Connect instruments

4 Carry out comparison measurement

5 Completion of the measurement

NOTICE: The procedure should only be carried out through qualified personnel.

6.5.1 Activate SWAN Quality assurance procedure

Enable quality assurance procedure at each instrument to be verified by selecting the quality level in menu 5.1.4.

The corresponding submenus are then activated.

NOTICE: The activation is necessary the first time only.

Quality Level

max. deviation temperature [°C]

max. deviation result [%]

min. inspection interval

0: Off

Off Off

Off

1: Trend

0.5 °C 10%

annual

2: Standard

0.4 °C 5%

quarterly

3: Crucial

0.3 °C 5%

monthly

4: User

0–2 °C 0–20%

annual, quarterly, monthly

a) sample temperature must have 25°C +/- 5°C.

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AMI Hydrogen QED

Maintenance

6.5.2 Pre-test

 Reference instrument: AMI Inspector Hydrogen:

– Check certificate; reference instrument certificate not older

than one year.

– Check battery; Battery of the AMI Inspector Hydrogen

should be completely charged. Remaining operating time on display minimum 20 hours.

– Sensor is in working condition.

 On-line instrument: Monitor AMI Hydrogen:

– Good order and condition; Flow cell free of particles,

Sensor surface free of deposits.

– Check message list; Review the message list in menu 1.3

and check for frequently occurring alarms (as for example flow alarms). If alarms occur frequently remove cause before starting the procedure.

6.5.3 Connect the sample lines

See corresponding chapter in the manual of the process monitor which shall be checked with a reference instrument.

The choice of sampling depends strongly on local conditions on site. Possible sampling:

 via sample point,  via T-fitting or  via piggyback/ downstream

NOTICE:

• avoid ingress of air, use screwed fitting,

• sample as near as possible to the process monitor,

• wait approx. 10 minutes, whilst measurement is running, until measurement value and temperature are stabilized.

Example As an example following picture shows the connection of the refer-

ence instrument via T-fitting to the process monitor.

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AMI Hydrogen QED

Maintenance

A-96.250.791 / 040219 43

1 Stop sample flow to the monitor AMI Hydrogen QED by closing

the appropriate valve, e.g. back pressure regulator, sample preparation or flow regulating valve at flow cell.

2 Connect sample line of the monitor AMI Hydrogen QED [A] with

the sample inlet of the reference instrument AMI Inspector Hydrogen [B]. Use the supplied tube.

3 Connect sample outlet of the reference instrument AMI Inspec-

tor Hydrogen to the sample outlet funnel of the monitor.

4 Switch on the AMI Inspector Hydrogen. Open the flow regulat-

ing valve and regulate the sample flow to 10 l/h. The actual flow is shown on the transmitter.

A B C D

Monitor AMI Hydrogen QED AMI Inspector Hydrogen Reference flow cell On-line flow cell

E F G

Sample outlet Sample inlet T-fitting

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AMI Hydrogen QED

Maintenance

6.5.4 Carry out comparison measurement

The comparison measurement is menu driven. Start by selecting Quality Assurance in menu 3.5 of the monitor AMI Hydrogen QED.

1 Navigate to menu Maintenance / Quality Assurance.

2 Press [Enter].

3 Follow the dialog on the Display.

4 Carry out pre test preparations

Connect instruments. Regulate sample flow to 10 l/h using the appropriate valve.

5 Wait 10 minutes whilst measure-

ment is running. Press [Enter] to continue.

6 Read the hydrogen value of the

reference instrument and enter under “Inspector.” by using the [ ] or [ ] keys.

7 Press [Enter] to confirm.

8 Read temperature value of the ref-

erence instrument and enter under “Inspector Temp.” by using the [ ] or [ ] keys.

9 Press [Enter] to confirm.

10 Press [Enter] to continue.



The results are saved in QA-

History regardless if successful or not

3.5.5

Quality Assurance

- Carry out preparations

- Install Inspector

- Sample flow to 10 l/h

<Enter> to continue

3.5.5

Quality Assurance

Value H2 0.05 ppb Value Temp. 25.00 C Wait 10 Minutes

<Enter> to continue

3.5.3

Quality Assurance

Value H2 0.05 ppb Value Temp. 25.00 C

<Enter> to continue

Inspector H2 0.06 ppb

Inspector Temp. 25.0 C

3.5.4

Quality Assurance

Value H2 0.05 ppb Value Temp. 25.00 C

<Enter> to continue

Inspector 0.06 ppm

Inspector Temp. 25.0 C

3.5.5

Quality Assurance

Max. Dev. H2 0.5 % Max. Dev. Temp. 0.4 °C

QA-Check succesful

Dev. H2 0.1 % Dev. Temp. 0.4 °C

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AMI Hydrogen QED

Maintenance

A-96.250.791 / 040219 45

6.5.5 Completion of the measurement

1 Stop the sample flow to the AMI Hydrogen QED by closing the

appropriate valve, e.g. back pressure regulator, sample preparation or flow regulating valve at flow cell again.

2 Close flow regulating valve of the AMI Inspector.

3 Disconnect the AMI Inspector by removing the tubes.

4 Start sample flow again.

5 Adjust the sample flow to 6–20 l/h. The actual flow is shown on

the transmitter display.

6 Shut down the AMI Inspector Hydrogen.

If the AMI Inspector will not be used for a longer period of time, proceed according to section Longer Stop of Operation in the manual of the AMI Inspector.

6.6. Longer Stop of Operation

1 Stop sample flow.

2 Do not shut off power of the instrument.

NOTICE: The hydrogen sensor is polarized and a loss of polarization will result in loss of sensitivity. If the AMI Hydrogen QED is switched off, the polarization buffer will be discharged within a few days.

3 Leave the sensor in the wet flow cell.

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AMI Hydrogen QED

Troubleshooting

7. Troubleshooting

7.1. Error List

Error

Non-fatal Error. Indicates an alarm if a programmed value is exceeded. Such errors are marked E0xx (bold and black).

Fatal error (blinking symbol) Control of dosing devices is interrupted.

The indicated measured values are possibly incorrect. Fatal errors are divided in the following two categories:

 Errors which disappear if correct measuring conditions are re-

covered (i.e. Sample Flow low). Such errors are marked E0xx (bold and orange)

 Errors which indicate a hardware failure of the instrument.

Such errors are marked E0xx (bold and red)

Error or fatal error Error not yet acknowledged. Check Pending Errors 1.1.5 * and

take corrective action. Press [ENTER].

Navigate to menu Messages. Press [ENTER].

Navigate to menu Pending Errors. Press [ENTER].

Press [ENTER] to acknowledge the Pending Errors. The error is reset and saved in the Message List.

* Menu numbers see

Program Overview, p. 50

25.4°C

HOLD

8 l/h

14:10:45

7.04 ppm

Installation

Operation

Diagnostics

Messages

Maintenance

Main Menu

1.1

Message List

Pending Errors

Maintenance List

Messages

1.1.5

Pending Errors

Error Code E002

Alarm low

<Enter> to Acknowledge

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AMI Hydrogen QED

Troubleshooting

A-96.250.791 / 040219 47

Error Description Corrective action

E001 Hydrogen Alarm high