User's Manual GC1000 Mark II Process Gas Chromatograph Overview IM 11B03A03-01E IM 11B03A03-01E 3rd Edition
◆ i Notice ● Regarding This Manual 1. This Manual should be passed on to the end user. 2. Read this manual carefully and fully understand how to operate this product before you start operation. 3. Yokogawa makes no warranty of any kind with regard to this material, but not limited to, implied warranties of merchantability for particular purpose. 4. All rights reserved. No part of this manual may be reproduced in any form without Yokogawa’s written permission. 5.
ii See Also: Gives the reference locations for further information on the topic. Protective ground terminal: In order to provide protection against electrical shock in case of a fault. This symbol indicates that the terminal must be connected to ground prior to operation of equipment. Function ground terminal: In order to provide protection against noise. This symbol indicates that the terminal must be connected to ground prior to operation of equipment.
◆ iii Warning/Caution Labels ● To ensure safety operation of this equipment, warning/caution labels are attached on the equipment as follows. Check these labels for your safety operation. D A C B E [Left side] [Front] [Right side] [Back] F0001.EPS A B C The inside of the enclosure is high temperature after turning off the power.
◆ iv Introduction Thank you for purchasing the GC1000 Mark II process gas chromatograph. This manual describes the technical information on overview of Model GC1000D / GC1000S / GC1000T / GC1000E / GC1000W / GC1000C (Hereafter, it is abbreviated as GC1000 Mark II) Process Gas Chromatograph. Please lead the following respective documents before installing and using the GC1000 Mark II system. ● Documents Related to the GC1000 Mark II Process Gas Chromatograph 1.
v 2. Operation Data Operation data is supplied with the operation manuals in the delivered package and contains the following required to use the gas chromatographs. ● ● ● ● ● ● ● ● ● Process conditions and measurement range Instrument specifications and operating conditions Standard sample for calibration Column system and column Miscellaneous data Chromatogram, base line, repeatability, power supply voltage variation, etc.
vi ● General Precautions WARNING (1) In order to analyze gases, process gas chromatographs use a sample of the process gas and utility gases. Since these gases are typically combustible, combustion-sustaining, toxic, odorous, resolvable, polymerizing, or corrosive, refer to the “Safety Information” in our approval drawings and others to ensure safety thoroughly before using these analyzers.
vii ● CAUTIONS OF USING EXPLOSION-PROTECTION INSTRUMENTS The GC1000 Process Gas Chromatographs are designed to protect against explosion. When these analyzers are used in a hazardous area, observe the following precautions. Since the applicable standard differs depending on the specifications of the analyzer to be used, check the specifications of your analyzer.
CSA viii Type X purging and Explosionproof for CLI, DIV1, GPS B, C & D, NEMA3R. Type Y purging and Type X purging for CLI, DIV1, GPS.B, C & D, NEMA3R. • T1 (programmed-temperature oven 320˚C max., isothermal oven 225˚C max., liquidsample valve 250˚C max.) • T2 (programmed-temperature oven 225˚C max., isothermal oven 225˚C max., liquidsample valve 225˚C max.) • T3 (programmed-temperature oven 145˚C max., isothermal oven 145˚C max., liquidsample valve 145˚C max.
ix (6) Maintenance and inspection During usual maintenance and inspection, it is not necessary to check the explosionprotected section. Before opening the door of the explosion-protected section for maintenance and inspection, be sure to turn off the power. After completing maintenance and checks, close the door completely then turn on the power after checking that the specified explosion protection performance is guaranteed.
x (9) Operation WARNING * Only trained persons may use this instrument in a hazardousl location. * Do not open when energized. For type X purging: * This equipment contains components that operate at high temperature. The equipment shall be deenergized for 60 minutes to permit those components to cool before the enclosure is opened unless the area is demonstrated to be nonhazardous at the time.
xi For type X purging: * This equipment contains components that operate at high temperature. The equipment shall be deenergized for 60 minutes to permit those components to cool before the enclosure is opened unless the area is demonstrated to be nonhazardous at the time. * Enclosure shall not be opened unless the area is known to be non-hazardous, or unless all devices within the enclosure have been de-energized.
xii ● Precautions Against Electrostatic Problems The GC1000 system uses numerous IC components. When handling cards with IC components mounted on them for maintenance or setting changes, take full precautions against electrostatic problems. These precautions are summarized below. (a) When storing or carrying cards, enclose them in a conductive bag or antistatic bag.
Toc-1 GC1000 Mark II Process Gas Chromatograph Overview IM 11B03A03-01E 3rd Edition CONTENTS ◆ Notice .......................................................................................................... i ◆ Warning/Caution Labels ............................................................................iii ◆ Introduction ...............................................................................................iv 1. Principle of Gas Chromatograph .....................
Toc-2 4.5 4.6 5. Actions of Calibration ...................................................................... 4-14 4.4.5 Actions of Validation ........................................................................ 4-17 Computation and Processing ...................................................................... 4-20 4.5.1 Peak Processing ............................................................................. 4-20 4.5.2 Deviation processing ..........................
1. <1. Principle of Gas Chromatograph > 1-1 Principle of Gas Chromatograph A gas chromatograph is an analyzer which first sends a fixed volume of the sampled multicomponent gas mixture to a column, separates it in the column, then measures the concentrations of the components with a detector. The process gas chromatograph analyzes intermittently, allowing periodic analysis in a specified sequence, thus automatic sampling is possible.
1.2 <1. Principle of Gas Chromatograph > 1-2 Component Separation Using Column Three types of columns are available for the GC1000 Process Gas Chromatographs: the packed column, the mega-bore column and the capillary column. The packed column consists of a stainless pipe, 2 mm in diameter and 0.2 to 2.0 m in length and filled with a bulking agent called a stationary phase. The mega-bore and capillary columns, of approximate diameter 0.5 mm and 0.
1.3 <1. Principle of Gas Chromatograph > 1-3 Detector The components separated in the column are led to the detector where the concentration of each component is measured. The GC1000 Process Gas Chromatographs can be fitted with thermal conductivity detectors (TCD), flame ionization detectors (FID) or flame photometric detectors (FPD). The thermal conductivity detector can measure almost all non-corrosive components but sensitivity is relatively low.
<1. Principle of Gas Chromatograph > 1-4 (2)Flame Ionization Detector (FID) The FID utilizes the phenomenon that carbon molecules in the measured component (hydrocarbon) are ionized in a hot hydrogen flame. That is, it detects the ionization current which flows between electrodes to which a high voltage is applied. The ionization current is proportional to the concentration of the measured component.
2-1 <2. Terminology > 2. Terminology 2.
2.2 2-2 <2.
3-1 <3. Overview > 3. System Configuration 3.1 Type and Appearance The GC1000 Process Gas Chromatographs consist of (A) a protection system, (B) an electronic section, (C) a pressure and flow control section, (D) an isothermal oven, (E) a programmed-temperature oven (GC1000D / GC1000T / GC1000W) and (F) an analyzer base sampling section (see Figure 3.1).
3.2 <3. Overview > 3-2 Components and Their Functions 3.2.1. Protection System The protection system has a explosion-proof construction and is equipped with a built-in protection circuit. The power relay, pressure switch, timer, relays, override switch, etc. are internal to the instrument. The override function is particularly important for maintenance, since it allows the power to be turned on even if there is an internal pressure loss.
3.2.5 <3. Overview > 3-3 Programmed-temperature Oven The programmed-temperature oven has an internal pressure protection / Type X purged structure. It contains a column that separates multi-component mixture samples into individual components and leads them to the detector in sequence. The temperature can be set to a fixed setting or it can be programmed.
3.3 3-4 <3. Overview > Block Diagram (1) GC1000D/GC1000T/GC1000W Type X Purging P.SW P.SW Terminal P.SW RELAY BOARD P.M BOARD Relay Relay Ether (*A) or (*B) is selected. AC/DC 15V AC/DC 24V AO BOARD AO BOARD AO BOARD AO BOARD AO BOARD AO BOARD AO MOTHER BOARD AO TERMINAL BOARD Terminal POWER UNIT COM BOARD COM BOARD SSR LCD AC/DC 24V SSR (*A) OPT CONVERTER Terminal MARSHALING.
3-5 <3. Overview > (3) GC1000S/GC1000E/GC1000C Type X Purging, with One Protection System P.SW Terminal P.SW RELAY BOARD P.M BOARD Relay Relay Ether (*A) or (*B) is selected. AC/DC 15V AC/DC 24V AO BOARD AO BOARD AO BOARD AO BOARD AO BOARD AO BOARD AO MOTHER BOARD AO TERMINAL BOARD Terminal POWER UNIT COM BOARD COM BOARD LCD AC/DC 3.3V AC/DC 24V (*A) OPT CONVERTER Terminal MARSHALING.
3-6 <3. Overview > (5) GC1000E Type Y Purging Ether (*A) or (*B) is selected. AC/DC 15V AC/DC 24V AO BOARD AO BOARD AO BOARD AO BOARD AO BOARD AO BOARD AO MOTHER BOARD LCD AC/DC 3.3V AC/DC 24V COM BOARD SSR COM BOARD SSR HUB TP BOARD (*A) OPT CONVERTER Terminal MARSHALING.Y BOARD (*B) TEMP CARD CPU CARD TERMINAL ETHERNET CARD AI CARD DET1 CARD DET2 CARD EV IF BOARD LCD.
3.4 3-7 <3. Overview > Internal Piping System Diagram (1) GC1000D/GC1000T/GC1000W Type X Purging Explosionproof enclosure 2 Explosionproof enclosure 1 Electric section (pressurized enclosure) REF Internal pressure detection switch Purge Purge 22 27 21 24 23 27 21 Pressure detection Isothermal oven 27 Fan SPLIT1 Vent B.F.1 Vent TCD1 Vent REF.1 Vent SPLIT2 Vent B.F.2 Vent TCD2 Vent REF.
3-8 <3. Overview > (2) GC1000T Type Y Purging Electric section (pressurized enclosure) REF Internal pressure detection switch 24 23 Isothermal oven 22 Pressure detection Fan SPLIT1 Vent B.F.1 Vent TCD1 Vent REF.1 Vent SPLIT2 Vent B.F.2 Vent TCD2 Vent REF.
3-9 <3. Overview > (3) GC1000S/GC1000E/GC1000C Type X Purging, with One Protection System Explosionproof enclosure 1 Electric section (pressurized enclosure) REF Internal pressure detection switch Purge 22 27 21 24 Pressure detection Isothermal oven 27 Fan SPLIT1 Vent B.F.1 Vent TCD1 Vent REF.1 Vent F.F.1-1 Vent F.F.1-2 Vent TCD2 Vent REF.2 Vent SPLIT2 Vent B.F.2 Vent F.F.2-1 Vent F.F.
3-10 <3. Overview > (4) GC1000S/GC1000E/GC1000C Type X Purging, with Two Protection Systems Explosionproof enclosure 2 Explosionproof enclosure 1 Electric section (pressurized enclosure) REF Internal pressure detection switch Purge Purge 22 27 21 24 27 21 Pressure detection Isothermal oven 27 Fan SPLIT1 Vent B.F.1 Vent TCD1 Vent REF.1 Vent F.F.1-1 Vent F.F.1-2 Vent TCD2 Vent REF.2 Vent SPLIT2 Vent B.F.2 Vent F.F.2-1 Vent F.F.
3-11 <3. Overview > (5) GC1000E Type Y Purging Electric section (pressurized enclosure) REF Internal pressure detection switch 24 Isothermal oven 22 Pressure detection Fan SPLIT1 Vent B.F.1 Vent TCD1 Vent REF.1 Vent F.F.1-1 Vent F.F.1-2 Vent TCD2 Vent REF.2 Vent SPLIT2 Vent B.F.2 Vent F.F.2-1 Vent F.F.
3.5 <3. Overview > 3-12 External Input and Output Signals (1)Input Item Signal level No. Description Analog Input Isolated 4-20mA DC 1-5V DC 4-20mA DC (with 24 or 28V DC of Power)*1) 4 Accuracy : ±0.
<3. Overview > 3-13 (3)Communication Item Signl level No. DCS communi-cation Standard : RS422 (4wires, Full-Duplex) Specification : Start bit 1, Stop bit 1, Parity 1, ASCII7 bit, Without procedure or Hand shake Speed : 1200/2400/4800/9600/19200 bps(selectable) For explosion protection : RS422/RS232C converter is provided.(2 wires of power line is needed except the signal line) The transmission type is full duplex for RS232C.
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4-1 <4. Outline of Software > 4. Outline of Software 4.
4.1.1 <4. Outline of Software > 4-2 Process In the Process status normal process measurements, calibration, and validation are performed. When power is applied, the status enters Process. The Process status contains the following measurement statuses.
<4. Outline of Software > 4-3 Three ways of calibration and three ways of validation can be used with the GC1000 Mark II. There are three methods for Calibration/Validation: automatic, semiautomatic and manual. The following explain the actions of three methods. •Automatic Calibration or validation is conducted automatically at the specified time. This function is only available when automatic valves are used for streams for calibration or validation.
<4. Outline of Software > 4-4 The following explain each operation mode in detail. (1) Stop In the Stop mode the measurement stops. When power is applied, the operation mode enters Stop. Settings should be changed in this Stop mode. CAUTION If settings are changed in an operation mode other than the Stop mode, the analyzer may not accept the change and run under the previous setting.
4.1.2 <4. Outline of Software > 4-5 Manual In the Manual status, various operations and measurements can be performed manually. The operations available in the Manual mode are: • On/off of various valves • On/off of stream valves • On/off of several heaters • On/off of several types of detector (only On for FID and FPD) When the status is transferred from Process to Manual, all the various valves and stream valves turn Off. The Manual mode contains the following operation modes.
4.2 <4. Outline of Software > 4-6 Stream In the GC1000 Mark II, 31 streams can be used. Parameters needed to be specified for streams are: • Stream valve number Any one stream valve number from among the numbers of 1 to 31 should be specified for a stream. If the stream valves are automatic, the stream valve of the specified valve turns on/off. If the stream valves are manual, this setting does not have any effect on the operation.
4.3 <4. Outline of Software > 4-7 Method Activation timing for various valves and parameters with regard to the temperature of the isothermal/programmed-temperature ovens should be specified for Method. Four Methods can be used with the GC1000 Mark II. Parameters needed to be specified are described below. For setting procedures, refer to the LCD Panel Operation Manual, IM 11B03A03-05 E.
4-8 <4. Outline of Software > • The first temperature gradient/first control temperature/first temperature time (only for the GC1000D/GC1000T/GC1000W) • The second temperature gradient/second control temperature/second temperature time (only for the GC1000D/GC1000T/GC1000W) • The third temperature gradient/third control temperature /third temperature time (only for the GC1000D/GC1000T/GC1000W) • Initial control pressure Displayed when EPC is installed that uses a pressure program.
4-9 <4. Outline of Software > In the case that EPC is installed, three stages of pressure program can be specified. Figure 4.4 shows the operations for EPC pressure programs.
4.4.1 4-10 <4. Outline of Software > Actions of Stream Sequence The same action is performed when the Stream Sequence is specified at any timing during analysis. (1) An action when the operation mode is transferred from Stop to Run while the measurement status is in Stream Sequence 1, is shown in Figure 4.5. Run command S1 W1 S2 W2 S3 W3 S1 W1 S2 W2 S3 W3 W1 Time Stream Sequence 1 S1 to S3: Analysis cycles for streams 1 to 3 W1 to W3: Warming up time for streams 1 to 3 F0405.
4.4.2 4-11 <4. Outline of Software > Actions of Stream (Continuous) Actions are different according to the timing when Stream (continuous) is specified. (1) An action when the operation mode is transferred from Stop to Run while the measurement status is in Stream (continuous) 2 and the operation mode is in Stop, is shown in Figure 4.8. Run command S2 W2 S2 W2 S2 W2 W2 S2 W2 S2 W2 S2 W2 Time Stream (Cont) 2 S2: Analysis cycles for stream 2 W2: Warming up time for stream 2 F0408.
<4. Outline of Software > 4-12 (4) An action when Stream (continuous) 4 is specified while the measurement status is in Stream Sequence 1 and the operation mode is in Run, is shown in figure 4.11. Select the Stream (cont) 4 S1 S2 W2 S4 W4 S4 W4 W4 S4 S4 W4 W4 Time Stream Sequence 1 Stream (Cont) 4 S1 to S4: Analysis cycles for streams 1 to 4 W1 to W4: Warming up time for streams 1 to 4 F0411.EPS Figure 4.
4.4.3 <4. Outline of Software > 4-13 Actions of Stream (1 cycle) Stream (1 cycle) 1 to 31 is allowed to be specified only when the measurement status is in Stream Sequence 1 to 4. The same action is performed when the Stream (1 cycle) is specified at any timing during analysis.
4.4.4 <4. Outline of Software > 4-14 Actions of Calibration Calibration 1 to 3 is allowed to be specified only when the measurement status is in Stream Sequence 1 to 4 or in Stream (continuous) 1 to 4. Actions are different according to the specified calibration (validation) method. • Automatic Calibration The same action is performed when the starting time comes at any timing during analysis.
<4. Outline of Software > 4-15 • Semiautomatic Calibration The same action is performed when the calibration is specified at any timing during analysis. (1) An action when Calibration 1 is specified while the measurement status is in Stream Sequence 1 and the operation mode is in Run, is shown in Figure 4.15.
<4. Outline of Software > 4-16 • Manual Calibration The same action is performed when the calibration is specified at any timing during analysis. (1) An action when Calibration 1 is specified while the measurement status is in Stream Sequence 1 and the operation mode is in Run, is shown in Figure 4.17. After Calibration 1 has been completed, the measurement status returns to Stream Sequence 1 and the operation mode turns to Stop.
4.4.5 <4. Outline of Software > 4-17 Actions ofValidation Validation 1 to 3 is allowed to be specified only when the measurement status is in Stream Sequence 1 to 4 or in Stream (continuous) 1 to 31. Actions are different according to settings. The same action is performed when the starting time comes at any timing during analysis.
<4. Outline of Software > 4-18 • Semiautomatic Validation The same action is performed when the validation is specified at any timing during analysis. (1) An action when Validation 1 is specified while the measurement status is in Stream Sequence 1 and the operation mode is in Run, is shown in Figure 4.21.
<4. Outline of Software > 4-19 • Manual Validation The same action is performed when the validation is specified at any timing during analysis. (1) An actin when Validation 1 is specified while the measurement status is in Stream Sequence 1 and the operation mode is in Run, is shown in Figure 4.23. After Validation 1 has been completed, the measurement status returns to Stream Sequence 1 and the operation mode turns to Stop.
4.5 <4. Outline of Software > 4-20 Computation and Processing The following are processed using chromatograms obtained as detection signals. For the setting procedure, see the LCD Panel Operation Manual, IM 11B03A03-05E. • Peak processing • Deviation processing • Additional processing • Signal processing Each processing is outlined below. For details, see the Technical Guide, IM 11B03A03-03E. 4.5.
4.5.4 <4. Outline of Software > 4-21 Signal Processing There are three types of processing in the signal processing: • Base level processing The detector signal at a time set for base level processing within the analysis cycle avoiding component signals is used as the base level value. If the base level processing is not set, the detector signal immediately after the start of analysis is employed as the base level value.
4.6 <4. Outline of Software > 4-22 Alarm Processing There are four alarm levels. For details of alarms, see the Alarm Message Manual, IM 11B03A03-06E. • Level 1 Alarms for system or hardware failures. When an alarm is generated, the alarm condition is maintained until it is reset. If a level-1 alarm is generated in the Run or Lab mode, the operation mode changes to Stop at the end of the measurement being executed. • Level 2 Alarms for measuring conditions failure.
<5. Actions of External Input and Output Signals > 5-1 5. Actions of External Input and Output Signals 5.1 Analog Hold Output Up to 36 outputs are available as option. Actions of analog hold output are different between when the actual stream is specified and when "99" is specified for the stream number in setting analog hold output. Actions of contact output are different whether a contact output is used or not as a stream identification signal.
5.1.1 <5. Actions of External Input and Output Signals > 5-2 When Actual Stream is Specified for Stream Number (without Stream Identification Signal) An action when analog hold output is specified as shown in Table 5.1, is illustrated in Figure 5.1. Table 5.1 Setting of Analog Output Output stream #1 Output peak #1 Output stream #2 Output peak #2 1 1 1 1 2 2 2 2 CH.1 CH.2 CH.3 CH.4 CH.5 CH.6 CH.7 CH.
5.1.2 5-3 <5. Actions of External Input and Output Signals > When Actual Stream is Specified for Stream Number (with Stream Identification Signal) An action when analog hold output is specified as shown in Table 5.2, is illustrated in Figure 5.2. Table 5.2 Setting of Analog Output Output stream #1 1 1 1 1 CH.1 CH.2 CH.3 CH.4 Output peak #1 Output stream #2 Output peak #2 1 2 3 4 1 2 3 4 2 2 2 2 T0502.
5.1.3 5-4 <5. Actions of External Input and Output Signals > When "99" is Specified for Stream Number (with Stream Identification Signal) An action when analog hold output is specified as shown in Table 5.4 under the peak setting conditions of each stream as shown in Table 5.3, is illustrated in Figure 5.3. Table 5.3 Conditions of Peaks for Streams Peak 1 Peak 2 Peak 3 Peak 4 Stream 1 Stream 2 Stream 3 Exist Exist Exist Exist Exist None Exist None Exist Exist None Exist T0503.
5.2 <5. Actions of External Input and Output Signals > 5-5 Contact Output The following five types can be specified for up to eight contact outputs as standard. • Stream Sequence • Stream • Operation Mode • Alarm • Timing Actions when each type is specified, are described below. CAUTION If settings are changed in the DO Setup panel while the contact output is On, the contact output may remain unchanged in On until the power is turned off and on.
5.2.2 <5. Actions of External Input and Output Signals > 5-6 Stream When the stream with the number specified in the DO Setup panel runs, the contact output turns On. Actions when Stream 1 is specified for Contact Output 1, are described below. (1) When the operation mode is changed from Stop to Run: When the Warming up time of Stream 1 starts, the contact output turns On.
5.3 <5. Actions of External Input and Output Signals > 5-7 Contact Input The following six types can be specified for up to eight contact inputs as standard. • Stream Sequence command • Stream (continuous) command • Stream (1 cycle) command • Calibration (Validation) • Operation Mode • Alarm processing CAUTION Contact input requires closed, pulse input. For input, closed, pulse input for at least 2 seconds must be performed.
5-8 <5. Actions of External Input and Output Signals > 5.4 Communication Input and Output 5.4.
5.4.2 <5.
<5.
5-11 <5. Actions of External Input and Output Signals > 5.4.
5.4.4 <5.
5-13 <5.
5.4.5 <5. Actions of External Input and Output Signals > 5-14 MODBUS Communication Data Specification (1) Coil (Command Contact) (1) Run command Commands the start of continuous analysis to the GC1000 Mark II. (2) Stop command Commands the stop of continuous analysis to the GC1000 Mark II. (3) Time setting request Requests the GC1000 Mark II to set the device clock to values in addresses 4000140004. Before this request, time should be set by a holding register.
<5. Actions of External Input and Output Signals > 5-15 (2) Input Relay (Status Contact) (1) Analyzer normal The GC1000 Mark II is normal. A 1 is displayed if there is no active level 1 (critical failure) or level 2 (minor failure) alarm. (2) Analyzer error The GC1000 Mark II is faulty. A 1 is displayed if there is at least one active level 1 (critical failure) alarm. (3) Alarm status change A 1 is displayed when a new alarm occurs on the GC1000 Mark II.
<5. Actions of External Input and Output Signals > 5-16 (3) Holding Register (Set Data) (1) Time setting value This is a set of four registers used by the DCS to set the device clock. When the time setting request coil (address 00003 for GC1000 Mark II and GCIU, 00001 for the analyzer server) is activated, these entries are used for the year, month/day, hour and minute/second.
<5. Actions of External Input and Output Signals > 5-17 (4) Input Register (Measured Data) (1) Stream number The currently active stream number on the GC1000 Mark II is displayed. In Stop or Manual mode, the stream number is 0. In Lab mode, the stream number is 32. (2) Starting peak number The starting peak number assigned to each stream on the GC1000 Mark II is displayed. The maximum number of analysis values, including peaks of all streams, is 255. The number is 0 if no peak is assigned.
<5. Actions of External Input and Output Signals > 5-18 (7) Calibration factor This register contains the calibration factor for each calibrated stream of the GC1000 Mark II. Since the factors are in the range of 0.000 to 9.999, each value is multiplied by 1000 and displayed as integers, i.e., 0000 to 9999. Table 5.5 Address Table (GC1000) Name Address Description Run command 00001 Recieved the message by the master, the slave reset.
i ◆ Revision Record ● Manual No. : IM 11B03A03-01E ● Title : GC1000 Mark II Process Gas Chromatograph Overview Oct. 2001/1st Edition Newly published July.
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