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550-350-007

GS-1000 plus VOC


Gasoline Analyzer
Operating Manual
P/N MAN GS-1000 Plus VOC Version 2

300 Bammel Westfield Road Houston, Texas 77090 USA Telephone: (281) 580-0339 (800) 444-8378 FAX: (281) 580-0719 e-mail: sales@paclp.com web site: http:/ /www.paclp.com

PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

THIS MANUAL CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION

which is the property of PAC. This manual and all information disclosed herein shall not be used to manufacture, construct, or fabricate the goods disclosed herein; shall not be exploited or sold; shall not be copied or otherwise reproduced in whole or in part and shall not be revealed or disclosed to others or in any manner made public without the express written permission of PAC.

REVISION HISTORY Rev Description Ver 1 First release Ver 2 Updates to format and content

Release Date April, 2004

Copyright 2004, by PAC, Houston, Texas. Printed in the United States of America All rights reserved. Contents of this publication may not be reproduced in any form without permission of the copyright owner. 04.01.04

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PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

TABLE OF CONTENTS

SECTION 1 INTRODUCTION ......................................................................................................... 1 General ...................................................................................................................... 1 Damage Claims .......................................................................................................... 1 Return Shipping ......................................................................................................... 1 Volatile Organic Compounds (VOC) ........................................................................... 1 SECTION 2 GENERAL INFORMATION ........................................................................................... 3 FOR BEST RESULTS FROM YOUR GS-1000 FUEL ANALYZER ......................................... 3 Tips For Properly Maintaining Your PetroSpec GS Series Instrument ............................ 3 Factory Default Settings ............................................................................................. 5 Sample Care And Preparation ..................................................................................... 6
Collecting And Storing A Retained Sample For Calibration Updating ............................... 6 Collecting And Analyzing Sample For Updating Gs Series Instrument .............................. 6 Updating Instruments .............................................................................................................. 6

Periodic Instrument Performance Validation by Control Charting ............................... 6 SECTION 3: PRODUCT DESCRIPTION ......................................................................... 11 Product Features ...................................................................................................... 11 The Technology ........................................................................................................ 11 Accessories Included ................................................................................................ 13 Parts and Accessories Available ................................................................................. 14 SECTION 4 BASIC OPERATING INFORMATION ............................................................................ 15 Safety ....................................................................................................................... 15 Controls ................................................................................................................... 15 The Power Switch .................................................................................................... 15 The Display .............................................................................................................. 15 The Keypad .............................................................................................................. 15 The Power Connection ............................................................................................. 15 The RS-232 Communication Port .............................................................................. 15 The Parallel Printer Port ............................................................................................ 15 GS-1000 Front and Back Panels............................................................................... 16 Fixed Arm Sample Induction System......................................................................... 17 Filter Housing .......................................................................................................... 17 Operate/Clean Switch ............................................................................................... 18 Cleaning Bottle Pressure Port ................................................................................... 18 Sample Input Port ..................................................................................................... 19 Sample Waste Port .................................................................................................... 20
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PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

SECTION 5 ANALYZING FUEL WITH THE GS-1000 PLUS VOC ...................................................... 21 Setting Up the GS-1000 ............................................................................................ 21 Sample Preparation .................................................................................................. 21 Analyzing Samples Quick Start Using the AUTO Function .................................... 22 Results Screens ......................................................................................................... 24 Mahalanobis Distance And Extrapolated Results ........................................................ 25 SECTION 6 ANALYZER SET-UP FUNCTIONS ................................................................ 27 1. PUMP ................................................................................................................... 27 2. PRINT ....................................................................................................................... 3. TIME ..................................................................................................................... 27 4. DEN (Density) ...................................................................................................... 28 5. VER (Version) ........................................................................................................ 28 6. VOC ..................................................................................................................... 28 7. Bias ...................................................................................................................... 29 8. UNIT .................................................................................................................... 30 Determining Weight Percent Oxygen ...................................................................... 30 SECTION 7 DATA MANAGEMENT FUNCTIONS ............................................................................................................. 31 Logging Analysis Results........................................................................................... 31 Entering Identification Codes ................................................................................... 31 Printing Data ........................................................................................................... 31 Erasing Data ............................................................................................................. 31 Exporting Data ......................................................................................................... 32 SECTION 8 USER UPDATEABLE CALIBRATION .......................................................................................................... 34 SECTION 9 PRODUCT MAINTENANCE ........................................................................................ 35 Cleaning the GS-1000 .............................................................................................. 35 Sample Induction Cleaning Procedure ..................................................................... 35 Replacing Fuel Filters ............................................................................................... 40

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APPENDIX 1 MESSAGES ............................................................................................................... 41 Extrapolated Result ................................................................................................... 41 Printer Fault Detected, No Connection Or Paper Feed Error..................................... 41 Hydrocarbons Detected, Please Power Down ........................................................... 41 Chopper Wheel Failure Detected .............................................................................. 41 Filter Wheel Failure Detected ................................................................................... 41 Source Failure Detected ........................................................................................... 41 APPENDIX 2 GASOLINE SAFETY INFORMATION ............................................................................ 45 Personal Protection Information ............................................................................... 45 Handling And Storage Precautions .......................................................................... 45 Reactivity Data .......................................................................................................... 45 Health Hazard Data .................................................................................................. 45
Acute Effects of Overexposure ............................................................................................. 45 Subchronic and Chronic Effects of Overexposure ............................................................. 45

First Aid And Emergency Procedures ....................................................................... 46 Fire And Explosion Data ........................................................................................... 46 Spill, Leak, And Disposal Procedures......................................................................... 46 Hazard Classification................................................................................................. 46 APPENDIX 3 WARRANTY INFORMATION ...................................................................................... 47 PETROSPEC WARRANTY REGISTRATION FORM ......................................................... 49 PetroSpec Warranty Registration Form ...................................................................... 49

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PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

SECTION 1 INTRODUCTION

General
Thank you for selecting the PetroSpec GS-1000 Gasoline Analyzer for your fuel analysis needs. We have designed the instrument to be accurate, durable, and easy to use, and we are confident that our product will perform to your satisfaction. Furthermore, we guarantee our product to be free of defects in materials and workmanship for a period of one year. This manual describes the correct operating procedure for the GS-1000 Gasoline Analyzer. The GS1000 is a product of PetroSpec, a subsidiary of PAC.

Damage Claims
Thoroughly examine your GS-1000 and all accompanying accessories as soon as they are received. NOTE: Insist that the carriers agent verify the inspection and sign the description. Immediately notify the delivering agent of damage or loss. This notification may be given either in person or by telephone. Written confirmation must be mailed within 48 hours. Railroads and motor carriers are understandably reluctant to make adjustments for damaged merchandise unless it is inspected and reported promptly. For technical support and customer service, please call 1-800-444-8378. Risk of loss of, or damage to, merchandise remains with the buyer. It is the buyers responsibility to file a claim with the carrier involved. Contact PAC Customer Service immediately so that we may assist you.

Return Shipping
All return shipments of PetroSpec products must be prepaid. If the product is damaged, return it in the original shipping container. PetroSpec will accept no liability for damage caused by improper packaging. Address all returns to: PAC, 300 Bammel Westfield Road, Houston, TX 77090. Please call PAC in advance, or enclose a detailed letter stating why you are returning your analyzer.

Volatile Organic Compounds (VOC)


Gasoline vapors and vehicle exhaust contain volatile organic compounds that react in the atmosphere in the presence of sunlight and heat to produce ozone, a major componenet of smog. Through the 1990 amendments to the Clean Air Act (CAA), Congress mandated that the Environmental Protection Agency (EPA) is responsible to regulate gasoline sold in certain areas to reduce vehicle emissions of such compounds. Thus the EPA developed the complex model (defined by EPA 40 CFR Ch. 1 [7-1-96 Edition] 80.45 Complex emissions model), a method by which VOC content can be measured, and reduction monitored. The GS1000 Plus VOC uses the complex model to calculate the total VOC (mg/mile) based on the operator entered values of RVP (psig) and sulfur content (ppm), along with predicted values of oxygen (wt.%), aromatic (vol.%), and olefin content (vol.%), as well as E200 (%) and E300 (%) predictions. The total VOC value is compared to a specified baseline gasoline (defined by region, season, and phase of the fuel being tested) to determine the percent reduction of the fuel sample.

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SECTION 2 GENERAL INFORMATION

WARNING! READ ALL SAFETY AND OPERATING INSTRUCTIONS BEFORE OPERATING This product must not be operated near the highly combustible environment of a fuel storage tank, vent, fill opening or dispensing systems. Fuel samples for analysis must be stored and handled in a closed container. Gasoline and gasoline vapors can create serious environmental, health, and fire hazards. It is the buyers responsibility to operate this product according to the instructions found in this manual.

For Best Results From Your Gs-1000 Fuel Analyzer


Caution: Do not attempt to use a cracked, chipped, damaged, or incompatible fuel sample container with the GS-1000 fuel analyzer. The GS-1000 pumps gasoline through the use of compressed air use of such containers may risk damage to the fuel delivery system or cause fuel to spill. 1. Tighten the sample bottle securely to the sample input port. 2. Replace the fuel filter every 50-75 fuel samples, and make sure that the fuel filter has not slipped during installation and that the fuel filter cap is tight. 3. Keep all tube fittings in good condition and replace any kinked tubing. 4. Always keep fuel samples covered. Evaporation will change the composition of the fuel and may affect the measured results. 5. The instrument will give best results after a thirty-minute warm-up time. 6. Operate the instrument at temperatures between 60 and 90 F (15 and 32 C). 7. Operate the instrument on a secure, stationary surface.

Tips For Properly Maintaining Your PetroSpec GS Series Instrument


1. When instrument is received, turn it on, warm it up for 30 minutes, and check the performance with a check standard. Check standards that are traceable to the factory validation of the instrument can be purchased from PAC. BTGS-17011 Check Standard with Ethanol, or BTGS17022 Check Standard with MTBE. Call for pricing and availability. PetroSpec recommends the users of this instrument periodically validate the performance of the instrument by constructing a control chart using a check standard. The procedure for developing a control chart is presented on page 10. 2. Be sure that the sample bottles are in good condition. Cracks could cause a premature pressure release that may invalidate the measurement. Chips on the top lip of the bottle not only can cause a loss of pressure, but they also can damage the gasket on the sample input port. 3. Never leave fuel in the instrument for an extended period of time. Always pump the fuel out of analyzer by running a sample with an empty bottle. A good practice to use is to flush the system with petroleum ether and then pump the system dry after the days use. 4. Change the fuel filter often. A dirty filter can diminish the flow of the instrument causing invalid results. If the fuel filter does not seat correctly sediment can bypass the filter and clog the sample cell.

PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

5. If there is a noticeable amount of particles in the fuel sample, pre-filtering the sample using a 20-micron or less pore size filter paper may be in order. 6. Be sure that the filter housing does not leak. Fuel stains on the left side panel are an indication that the housing is leaking. A leak not only causes unsightly stains but the leak could also cause invalid measurements. 7. A minimum flow rate of three milliliters is recommended for proper operation of the instrument. To check for proper flow, first prime the instrument, (run a sample into the waste bottle) then, using a graduated cylinder as the waste vessel, run another sample. The pump time is set at the factory for fifty seconds. If the instrument does not pump a minimum of three milliliters in this time then the pump can be increased. NOTE: If 3ml or more of sample flow cannot be obtained in ninety seconds or less, it may indicate that the instrument needs service. 8. Always use clean bottles to introduce the sample into the instrument. Cross contamination could occur if the bottles are not clean. Sediment in the bottle can result in a clogged system. 9. Screw the red fuel fittings into the sample input port firmly and be sure not to over-tighten. A fitting that is too tight could restrict the fuel flow. Use care in tightening the fitting cross threading could result in a fuel and or pressure loss that could invalidate the measurement. If the threads of the RED fitting become stripped or the tubing gets kinked, please call PetroSpec. We offer replacement tubing kits: Model Number BTGS-1402 for Coaxial Side Arm: Model Number BTGS-1403 for Boston Round Side Arm. 10. If you have any problems or questions please do not hesitate to call us at 281-580-0339.

PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

Factory Default Settings


Your GS-1000 arrives with the following factory preset defaults. Pump Time Print Format Time Density MeOH ------------------------------------------------------------------- .796 EtOH --------------------------------------------------------------------- .794 TBA ---------------------------------------------------------------------- .792 MTBE -------------------------------------------------------------------- .746 DIPE --------------------------------------------------------------------- .730 ETBE --------------------------------------------------------------------- .745 TAME ------------------------------------------------------------------- .755 GAS ---------------------------------------------------------------------- .742 Version ----------------------------------------------------------------------------- Revision Dependent Demo Mode ----------------------------------------------------------------------- Off Bias Aromatics -------------------------------------------------------------- 0 Benzene ----------------------------------------------------------------- 0 MTBE -------------------------------------------------------------------- 0 MeOH ------------------------------------------------------------------- 0 TAME ------------------------------------------------------------------- 0 ETBE --------------------------------------------------------------------- 0 EtOH --------------------------------------------------------------------- 0 DIPE --------------------------------------------------------------------- 0 TBA ---------------------------------------------------------------------- 0 Research Octane Number --------------------------------------- 0 Motor Octane Number -------------------------------------------- 0 VOC E200 ---------------------------------------------------------------------- 0 E300 ---------------------------------------------------------------------- 0 Volatility T50 ----------------------------------------------------------------------- 0 T90 ----------------------------------------------------------------------- 0 Temperature ---------------------------------------------------------- Location Dependent Unit ----------------------------------------------------------------------------- Vol% Total Oxygen --------------------------------------------------------------------- Wt% NOTE: The Total Oxygen values are expressed in Wt% only and cannot be changed. ----------------------------------------------------------------------------- 50 Seconds ----------------------------------------------------------------------------- Table Format ----------------------------------------------------------------------------- Eastern Standard Time

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Sample Care And Preparation


Collecting And Storing A Retained Sample For Calibration Updating
1. Samples should be stored in an amber bottle with a cap that has a conical insert. 2. Bottles must be tightly capped. 3. Store retained samples in an explosion proof refrigerator at 5 degrees Celsius. 4. Opening of the samples should be avoided. The lighter components of the fuel escape every time the cap is opened. This will change the composition of the fuel.

Collecting And Analyzing Sample For Updating Gs Series Instrument


1. Draw a single sample from the tank or pipeline. 2. Split the sample into appropriately sized containers. Retain a portion of the sample to be used later for updating. Submit the remaining sample for laboratory analysis. The samples must be packaged and cared for in accordance with instructions presented in the previous section. 3. The laboratory should analyze the samples immediately to avoid weathering.

Updating Instruments
1. Bring the sample to room temperature. 2. Make sure the fuel filter is clean. Replace the filter if it is tan to brown in color. 3. Set up the instrument as described on page 22. 4. Run a check sample in the GS-1000 before adding fuels. The results for the check sample must fall within the limits established by the instrument control chart (page 8). Repeat the analysis of check standard if the sample results fall outside the control limits. If the results for the check sample continue to fall outside the control limits call PetroSpec Customer Service. It is very important to make sure the unit is operating properly before adding fuel. 5. Laboratory results must be available before the GS-1000 can be updated. The outside analysis and sample data will be used to update the instrument. 6. Use the Calibration Update Software to download the absorbance data from the samples that are to be used for the calibration update. Refer to the Calibration Update Software Manual for more detailed instructions.

Periodic Instrument Performance Validation by Control Charting


It is important to periodically monitor the performance of the GS-1000 and to demonstrate that the current performance is statistically consistent with the historical performance of the instrument. Constructing a control chart is the best method for validating the performance of the instrument. This section will describe the procedure for constructing an individual differences control chart. The control chart is used to plot the difference between the stated property value of a check standard and the property value determined by the instrument. Since the control chart is plotting the difference between the expected value and the predicted value, it is not necessary to begin a new control chart if the expected value for the check standard changes. For example, if the new check standard is from a different batch. Benzene is the property used for the example described in this section. The data required for constructing the control chart for benzene is presented in Table 1.

PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

TABLE 1. BENZENE CONCENTRATIONS, IN VOLUME PERCENT FROM A PETROSPEC CHECK SAMPLE

Date 05/21/98 05/28/98 06/03/98 06/15/98 06/12/98 06/17/98 06/24/98 07/01/98 07/12/98 07/19/98 07/31/98 08/08/98 08/15/98 08/22/98 08/30/98 09/06/98 09/13/98 09/20/98 09/27/98 10/02/98 10/09/98 10/16/98 10/23/98 11/01/98

Sample (n) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Expected 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19

Predicted 2.19 2.21 2.19 2.20 2.22 2.18 2.22 2.17 2.19 2.20 2.24 2.20 2.23 2.23 2.23 2.22 2.16 2.16 2.16 2.18 2.16 2.18 2.17 2.19

Diff. (dn ) 0.00 -0.02 0.00 -0.01 -0.03 0.01 -0.03 0.02 0.00 -0.01 -0.05 -0.01 -0.04 -0.04 -0.04 -0.03 0.03 0.03 0.03 0.01 0.03 0.01 0.02 0.00

MR (|dn+1-dn|) 0.00 0.02 0.02 0.01 0.02 0.04 0.04 0.05 0.02 0.01 0.04 0.04 0.03 0.00 0.00 0.01 0.06 0.00 0.00 0.02 0.02 0.02 0.01 0.02

The expected value is the certified benzene concentration of the check sample, the predicted value is the benzene concentration determined using the instrument, and the difference, dn, is the difference between the expected value and the predicted value for sample n. The value MRn is calculated by taking the absolute value of the difference between dn and dn-1 Examples: For the sample number 2 analyzed on 5/28/98, d2 = 2.19 2.21 = -0.02 and MR2 = |d2 d 1| = | -0.02 0.00| = 0.02. For the sample number 6 analyzed on 6/17/98, d6 = 2.19 2.18 = 0.01 and MR6 = |d6 d5| = |0.01 (-0.03)| = 0.04. The upper control limit (UCL) and lower control limit (LCL) are calculated using the equations: UCL = dave + 2.66*MRave LCL = dave - 2.66* MR ave

PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

The value dave is the running average of the differences dn. For the data listed in Table 1, dave is calculated by summing the values for d1 through d24 and dividing the sum by 24 yielding the value 0.005. The value MRave is the running average of the absolute value of the difference between dn and dn-1. In this example, MRave is calculated by summing the values for MR1 through MR24 and dividing the sum by 24 yielding the value 0.022. The values for UCL and LCL are 0.053 and 0.063, respectively. Examples: For the sample number 2 analyzed on 5/28/98, UCL = [(0.00+(-0.02))/2]+2.66*[(0.00+0.02)/2] = 0.0166 and LCL = [(0.00+(-0.02))/2]-2.66*[(0.00+0.02)/2] = -0.0366. For the sample number 6 analyzed on 6/17/98, UCL = [(0.00+(-0.02)+0.00+(-0.01)+(-0.03)+0.01)]+2.66*[(0.00+0.02+0.02+0.01+ 0.02 + 0.04)/6] = 0.0405 and LCL = [(0.00+(-0.02)+0.00+(-0.01)+(-0.03)+0.01)/6]-2.66*[(0.00+0.02+0.02+0.01+ 0.02 + 0.04)/6] = -0.0571. The graph in Figure 1 is a graphical representation of the data summarized in Table 1 and is called a control chart, specifically the Individual Differences control chart. The graph is a plot of dn versus the sample number, n. Each time the control sample is analyzed the difference dn is calculated. If the difference value, dn, falls within the upper and lower control limits, recalculate the UCL, and LCL, and plot the new d-value.
Figure 1. Control chart for benzene concentration determination

Benzene Control Chart


0.10 0.08 0.06 0.04 0.02 0.00 -0.02 -0.04 -0.06 -0.08 -0.10 0 5 10 15 Sam ple Num ber 20 25 30 d

UCL

LCL

PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

If the difference, dn, falls outside the upper or lower control limit, the instrument and/or the check sample appears to be unstable, and efforts should be made to determine the cause. Check the fuel filter, and the hose connections to ensure the sample is being properly introduced into the instrument, then re-analyze the check sample. If the result continues to fall outside the control limits contact PAC Customer Service. When adding a check sample result to the control chart, it is important not to bias the statistics by adding more than one result for each check sample. The interval between check samples is variable but should not be longer than one week or every 50 samples, whichever interval is shorter, during the initial period of testing. As the trend of the instrument performance is established, the interval between check samples can be increased, however the interval should not be more than one month. The more often the instrument is used, the more often a check sample should be tested. A control chart should be constructed for every parameter reported by the GS-1000 and recorded by the user. Check standards can be purchased directly from PAC. Model numbers BTGS-17011 for ethanol or BTGS-17022 for MTBE. They come in packs of 5 vials. Call for price and availability.

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SECTION 3: PRODUCT DESCRIPTION

Product Features
The GS-1000 Gasoline Analyzer provides a fast, accurate analysis of fuel composition in the field or laboratory. In one simple, two-minute analysis process, the instrument reports the following:
Component Research Octane Number (RON) Motor Octane Number (MON) Pump Octane Number (R+M/2) Oxygenates: MTBE ETBE Ethanol Methanol TAME DIPE TBA Total Oxygen Benzene Total Aromatics Olefins Saturates Toluene Xylene T50 T90 E200 E300 Total VOC VOC Redirection Calibration Range 90-101 80-90 Calculated 0-20 vol % 0-24 vol % 0-15 vol % 0-8 vol % 0-24 vol % 0-20 vol % 0-15 vol % Calculated 0-5 vol % 0-60 vol % 0-35 vol % Calculated 0-25 vol % 0-15 vol % 150-265 F 265-360 F 30-70% 75-95% Calculated Calculated

Note: The calibration ranges stated above are the ranges found in the standard factory calibration. Certain ranges can be expanded higher and lower via calibration update. Please call PAC at 281-580-0339 for more information.

The Technology
The GS-1000 Multi-Function Analyzer uses a mid-infrared spectroscopic analysis technique to differentiate and quantify the individual components in a fuel sample. Every fuel component has a unique spectral absorbance pattern that contains characteristic absorbance bands. The GS-1000 utilizes a proprietary set of optical band-pass filters to measure the amount of energy that is absorbed by a fuel sample at these identifying bands. The amount of light absorbed is proportional to the concentration of that component in the fuel sample. The instrument predicts the property value of a fuel sample using a model that relates the mid-infrared absorbance of the sample to the property value for the sample. The model is developed using the concentrations and inter-relations of the many components in a set of calibration samples having defined property values. The GS-1000 utilizes a thermoelectric temperature control system. The temperature control system requires an external thermal management system, which consists of a thermal bus, a fan, a thermal shield, and a heat sink. The thermal bus is mounted on the bottom of the instrument and transfers thermal energy to or from the optical system to the heat sink, which is located on the right side of the instrument. The thermal shield covers the thermal bus on the bottom of the instrument.

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The thermal electric temperature control system may need to heat or cool the GS optical system in order to maintain the optimum internal temperature. This heating or cooling mode is dependent on the external temperature. The instrument must obtain thermal equilibrium before accurate analyses can be made, therefore, a warm up period of 30 minutes (minimum) is required before running any fuels. The temperature control system can maintain optimum temperature within the GS-1000 when external temperature is between 60 and 90 degrees F. In order to maintain this operating range, there must be free air circulation around the thermal bus and the heat sink. It is important to keep the immediate area around the heat sink clear of obstructions. It is equally important that the exhaust fan vents be kept clear and unobstructed.
Product Specifications Sample Size Data Output Dimensions Weight Operating Temperature Range Power Requirements Property RON MON R+M/2 Total Aromatics Total Olefins Saturates Total Xylenes *Benzene *MTBE *EtOH *TAME *ETBE *DIPE *TBA *MeOH *Wt. % Oxygen T50 T90 E200 E300
*From ASTM Round Robin

5 ml minimum 2 lines x 40 character LCDRS-232 serial portParallel printer port 10.5W x 11.0D x 12.5H (inches) 26 pounds 60 F - 90 F 120/240 VAC 50/60 Hz Reproducibility .013*(X + 2) .64 .81 .97*X^.25 .076*(X + 14.89) 2.8 .3 .121 + (.012*X) .98 .59 1.36 .77 .79 .59 .37 .3 Test Method Correlates to D2699 Correlates to D2700 Correlates to D1319 Correlates to D1319

Repeatability .0022*(X + 2.0) .11 .17 .17*X^.25 .019*(X + 11.43) .67 .1 .021 + (.027*X) .13 .13 .13 .15 .14 .1 .07 .05

D6277 D5845 D5845 D5845 D5845 D5845 D5845 D5845 D5845 Correlates Correlates Correlates Correlates

to to to to

D86 D86 D86 D86

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Accessories Included
Your GS-1000 is shipped with the following accessories:

120/240 VAC external power supply 4 large (8 oz.) sample bottles 4 small (4 oz.) sample bottles Calibration Update Manual Or Cleaning Cap 20 Teflon fuel filters Tubing kit User Calibration Software CD Instrument Database Diskette 1 Serial Cable GS-1000 Operating Manual Accessories Price List Certificate Of Compliance WARNING: Only use the 120/240 VAC external power supply designated for the GS-1000 series instruments.

For your convenience, the following accessories are available directly from PetroSpec:

Sample bottles Replacement fuel filters Replacement tubing kits Air shippable carrying case Replacement 120/240 VAC external power supply Instrument Check Standards

The following page contains a complete list of GS accessories. For pricing and ordering information, please call PAC at 281-580-0339.

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Parts and Accessories Available


PETROSPEC ACCESSORIES AND PARTS Description Large 8 oz., Glass Bottles w/ Plastic Armor (Box of 5) Small 4 oz., Glass Bottles clear w/o Plastic Armor (Case of 24) Small 4 oz., French Square Bottles (Case of 24) Fits Boston Round Cap Glass Vials 20 ml., Clear w/o Plastic Armor (Case of 100) Teflon Fuel Filters (Pack of 20) BTGS-1420 Tubing & Compression Fittings for Co-axial Cap (Set of 4) Tubing & Compression Fittings for Boston Round Cap (Set of 4) Power Supply & Cord for GS-360 & GS-500 Power Supply & Cord for GS-1000 (120/240 VAC) (Auto Switching for International Use) Auto Cigarette Lighter Adapter (For use with GS-360 &GS-500) Auto Cigarette Lighter Adapter (For use with GS-1000) Surge Protector Soft-Sided Carrying Case Gasoline Analyzer Check Standard with Ethanol Gasoline Analyzer Check Standard with MTBE (Five 20 ml Vials) Suitable for GS-1000 GS-360, GS-500, GS-1000PlusVOC series Boston round bottle threaded ring and gasket for fixed arm assembly. Fits GPI 33-400 bottle thread Model BTGS-1301 BTGS-1320 BTGS-1325

BTGS-1330

BTGS-1402 BTGS-1403 BTGS-1501 BTGS-1240

BTGS-1503 BTGS-1504 BTGS-1510 BTGS-1702 BTGS-17011 BTGS-17022

BTGS-BRSIA

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SECTION 4 BASIC OPERATING INFORMATION

Safety
The GS-1000 should not be operated near the highly combustible environment of an underground fuel storage tank, vent, fill opening, or dispensing system. The GS-1000 contains a hydrocarbon sensor that can detect potentially explosive levels of gasoline vapors. If dangerous levels are detected, the GS-1000 will automatically shut off all power to its infrared source and will alert the user to power down the instrument.

Controls
The GS-1000 is designed to be easy to use. This section will familiarize you with the few buttons and connections that will enable you to use the GS-1000 to its fullest capacity.

The Power Switch


The power switch turns the GS-1000 on and off. Upon powering up, the instrument completes an initialization and self-diagnostic procedure that takes approximately five minutes. This period also allows the infrared filament source within the GS-1000 optical system to warm up. Although the instrument can be used immediately after the initialization period, for best results it is recommended that a minimum warm-up period of 30 minutes be observed.

The Display
The GS-1000 features a 2 line x 40 character back-lit LCD display. All analysis results and menu choices are shown on the display. When the displayed information does not fit onto one screen, the arrow keys are used to scroll through multiple screens of data.

The Keypad
The GS-1000 keypad features 12 numerical keys (left side) and 8 control keys (right side). The numerical keys are used primarily to enter menu choices. The control keys are used to verify menu selections, scroll through analysis results screens, and for data management.

The Power Connection


The power connection is located on the rear panel of the GS-1000. Power is supplied by the 120/240 VAC external power supply shipped with the unit. Only use power supplies designated for use with the GS-1000 or GS-1000 series of instruments.

The RS-232 Communication Port


The RS-232 serial port is located on the rear panel of the GS-1000. The RS-232 serial port allows the user to download data from the GS-1000 to a computer. For more information see Section 7, Data Management.

The Parallel Printer Port


The parallel printer port allows analysis reports to be printed directly from the GS-1000 to any parallel printer compatible with the Centronics protocol.

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GS-1000 Front and Back Panels

Fixed Arm Sample Induction System


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Fixed Arm Sample Induction System

(Fixed Arm Features photo)

Filter Housing
The filter housing contains the fuel filter disc. To access the filter, simply unscrew the knurled screw and lift up on the hinged filter housing top plate. If the filter housing is dry the filter may become difficult to remove. To aid in the ease of filter removal PetroSpec recommends that a fuel sample be run on the instrument prior to changing the fuel filter. NOTE: Be sure that the sample bottle is disconnected from the sample input port when replacing the fuel filter. The pressurized fuel in the sample bottle will flow during fuel filter replacement if the sample bottle is still attached. Be sure to close the filter housing and tighten the knurled screw after the filter has been replaced and before running fuel samples.

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Operate/Clean Switch
The Fixed Arm Sample Induction System features a Operate / Clean toggle switch. The purpose of the toggle switch is to allow the user to easily and effectively clean the sample induction system of the analyzer. The switch must be in the up position for normal fuel sampling operations. With the switch in the up position the instrument will pressurize the fuel sample bottle to allow adequate fuel flow for the test being performed. Placing the switch in the down position will redirect the pressure to the quick disconnect fitting located on the left side panel of the instrument for cleaning operations. Please refer to the cleaning instructions on page 35 for additional information on cleaning the instruments sample induction system. Warning: Running fuel samples without the fuel filter being installed may result in a clogged Sample Induction System.

Cleaning Bottle Pressure Port


The pressure port is use during cleaning operations. Use the Cleaning Cap located in the accessory kit when cleaning operations are performed. The pressure hose must be connected to the pressure port on the side panel of the instrument during this operation. Please refer to the figure below for proper cleaning set up.
Fuel analyzer set up for cleaning operation

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Sample Input Port


Fuel samples are introduced into the analyzer via the Sample Input Port. There are two styles of Sample Input Ports available from PetroSpec. The most common option is the Coaxial Sample Input Port. The Coaxial Sample Input Port is designed to accommodate sample bottles with GPI thread sizes 22-400 or 45-400. The second option is the Boston Round Sample Input Port. This port accommodates bottles with a GPI thread size of 33-400. Please refer to the chart below for the Sample Input Port Options and the mating sample bottles that are available from PetroSpec.
Sample Port Type Coaxial Sample Input Port Thread Size Sample Bottles Available 22-400 20 ml vial 4 oz clear bottle 8 oz amber bottle with armor 4 oz French Square bottle Part Number BTGS-1330 BTGS-1320 BTGS-1301 BTGS-1325 (Case (Case (Case (Case of 100) of 24) of 5) of 24)

Boston Round Sample Input Port 33-400

For best results, fill the sample bottle at least full of gasoline sample. Be sure to use the proper dip tube for the sample bottle selected. Screw the sample bottle firmly onto the Sample Input Port but to avoid breakage do not over-tighten.

Be sure to select the correct length dip tube to match the chosen sample bottle.

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Sample Waste Port


Connect the amber waste bottle to the Sample Waste Port. To avoid bottle breakage, do not over-tighten.
Standard sample run set-up

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SECTION 5 ANALYZING FUEL WITH THE GS-1000 PLUS VOC

Setting Up the GS-1000


The GS-1000 is factory calibrated and is ready to use. Power is supplied through the 120/240VAC external power supply. Plug the power supply into the power socket on the rear of the GS-1000 and turn the power switch to the ON position. The GS-1000 will perform a five-minute self-test and initialization procedure, followed by a 25-minute warm-up period in which the screen will be flashing. After the warm-up period the main menu will stop flashing. During the initialization/warm-up period, the condition of the fuel filter should be checked and replaced if necessary (See Section 9: Product Maintenance). NOTE: Best results will be obtained if the analyzer is allowed to warm up for at least 30 minutes. If the instrument is momentarily shut down after the 25-minute warm-up has taken place due to a fuel spill or any other reason then the 25 minute warm-up period can be overridden simply by pressing the (1) AUTO KEY.

Sample Preparation
All fuel samples for analysis must be in a container that is compatible with the GS-1000 fuel delivery system. There are two Fixed Arm Induction options. The most common option is the coaxial Fixed Arm Induction Port. The Coaxial Fixed Arm Induction Port is designed to accommodate sample bottles with GPI thread sizes 22-400 or 45-400. The second option is the Boston Round Fixed Arm Induction Port. The Boston Round Fixed Arm Induction Port accommodates bottles with a GPI thread size of 33-400. A minimum sample size of 5 ml is required for analysis. However, best results are obtained with relatively full sample containers.
Standard sample run set up.

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Analyzing Samples Quick Start Using the AUTO Function


Verify that the sample and waste fuel bottles are properly connected. Attach the appropriate sample inlet tube, based on the size of your sample container, to the Sample Input Port (see figure on page 17). Screw sample bottle securely onto the Sample Input Port. The sample bottle must be snug but use care not to over-tighten in order to prevent damage to the gasket, sample bottle, or both. NOTE: Be sure that the Clean / Operate switch is in the Up position prior to running fuel samples.
The GS-1000 plus VOC Main Menu

At the main menu, press AUTO (1). The GS-1000 will prompt the user for an expected R+M/2 value. If desired, the user may enter the rated R+M/2 value. This will be logged and printed along with the analysis results for the purpose of comparison or identification of the sample. The entered R+M/2 value has no effect on the results of the analysis. After entering the expected R+M/2 value (or EXIT if the user chooses not to do so) analysis cycle will begin, which consists of approximately one minute of pumping fuel followed by two minutes of analysis. The GS-1000 will automatically begin a complete analysis cycle, which includes the determination of all oxygenates, benzene, total aromatics, toluene, xylene, total olefins concentrations; as well as the prediction of the octane, and distillation points (T50, T90). The weight percent oxygen, the percent of saturates, and the R+M/2 octane values are determined by calculation. Upon completion, analysis results will be displayed on the screen. Use the arrow keys or the ENTER key to scroll from one screen of analysis results to the next.

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Menu Flowchart
Auto Function

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Results Screens

Pressing ENTER on the eighth screen will display all results again starting from the first screen. Press EXIT while on the eighth screen to exit the analysis results screen. The GS-1000 will allow the operator to choose whether to log the results. Press NO to run another analysis without logging the current results. For information on logging results, see Section 7: Data Management. Note: Be sure to pump the instrument dry after the days use.

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Mahalanobis Distance And Extrapolated Results


The GS-1000 uses a statistical value called the Mahalanobis distance to determine whether the predicted property values obtained from a fuel sample result from an extrapolation of the model. The extrapolation of the model occurs when the infrared spectrum of the fuel sample is not included within the spectral space spanned by the calibration fuels used to construct the model. When the Mahalanobis distance detects that the predicted property value of the fuel sample is likely the result of an extrapolation, the instrument warns the user of the extrapolated result along with the Mahalanobis distance number, which is displayed as M=**.*. The Mahalanobis distance warning is triggered when the distance value exceeds 26.3. If the absorbance values from the calibration set are normally distributed, then the Mahalanobis distance follows the chi-squared distribution. For 16 degrees of freedom (17 filters minus one), a sample with a Mahalanobis distance of 26.3 is deemed to be outside the calibration set with 95% confidence. Depending on the magnitude of the Mahalanobis distance, one or more samples similar in composition should be added to the calibration set. The addition of one sample may not eliminate the extrapolation. An outlier with a large Mahalanobis distance (>50) may not be made an inlier no matter how many samples of similar composition are added to the calibration set. For a sample with a large Mahalanobis distance, a separate calibration set may need to be constructed. The ability of the analyzer to predict the properties of a specific fuel may improve if the sample is added to the calibration set. See User Calibration Section 8 page 33. For detailed information, refer to the Calibration Update Manual.

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SECTION 6 ANALYZER SET-UP FUNCTIONS

The set-up functions allow the user to modify the GS-1000s basic operating parameters. The correct use of these functions allows the user to customize the operation, or modify the results of the instrument. However, improper use of these functions may negatively impact the accuracy of the GS-1000. Therefore, only qualified, trained personnel should change any of these settings. To access the set-up functions, press SETUP (4) from the GS-1000 main menu.

The set-up menu will appear:

1. PUMP

The PUMP function allows the user to set the length of time that the fuel pump operates before analysis begins. The GS-1000 should pump at least 3ml of fuel through the system within the selected pumptime. This sample volume will displace the previous sample. A pump-time of less than 50 seconds is not recommended. If 50 seconds is not an adequate pump time, try replacing the fuel filter and checking the fuel lines for kinks before adjusting the pump time. For more information, see Section 9: Product Maintenance. To adjust the pump time, press PUMP (1) from the set-up menu. Enter the new pump time and press ENTER.

2. PRINT

The PRINT Set-Up function sets the format of printed analysis results. You can select either TABLE (1) or REPORT (2) format. The table format lists the sample identification code, the time and date the analysis was run, and all analysis results. The report format prints the same information but leaves room for a description of the sample, results from running a calibration standard, and a place for the operators signature.

3. TIME
PUMP PRINT TIME DEN VER VOC BIAS UNIT (1) (2) (3) (4) (5) (6) (7) (8)
The TIME function allows the user to change the time and date. Select TIME (3) and enter the new time and date.

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4. DEN (Density)

The GS-1000 calculates total weight percent oxygen from volume percent using the EPA method described on page 64 of the Supplemental Notice of Proposed Guidance on Establishment of Control Periods under Section 211 (m) of the Clean Air Act as amended and released in the first quarter of 1992. The specific densities used in the calculation are also from this method:
Oxygenate MTBE EtOH TAME ETBE MeOH DIPE TBA GAS Weight percent Oxygen 18.15 34.73 15.66 15.66 49.93 15.66 21.59 Density 0.746 0.794 0.755 0.745 0.796 0.730 0.792 0.742

For greater control over the accuracy of the total weight percent oxygen measurement, you may enter your own values for the specific density of each oxygenate component and of the base gasoline. To do this, select 4 (DEN) choose the desired component or gasoline, type the new three digit density value, and press ENTER. The GS-1000 always displays the EPA designated value in parentheses when the screen is accessed.

5. VER (Version)

Selecting the version function will enable the operator to see the current firm ware version of the instrument. The version function also allows the user to put the GS-1000 into the demonstration mode. When the instrument is in the DEMO mode it goes through all the motions of an analysis but only displays demonstrated results. The letter d will be displayed on the LCD while the instrument is in this mode. Note: Be sure to disable the DEMO mode once the demonstration is completed.

6. VOC

The VOC set-up function allows the operator to disable or enable the VOC mode, set the VOC region, and set the VOC season.

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7. BIAS

The BIAS function allows the user to add or subtract an offset to the final oxygenate, xylene, toluene, total aromatic, benzene, olefin, octane, T50, or T90 analysis result. The BIAS sub-menu allows the user to select which analysis (oxygenate, aromatic, octane, evaporation point, or VOC) is to be offset. The user may then increment, decrement, or clear existing offsets. When an oxygenate bias is entered, the letter x will appear on the display in the main menu. When an octane bias is entered, the letter e (for engine) will appear on the display in the main menu. Please refer to the chart below for other letter designations and their respective biasing.
Measured Property Demo mode Oxygen bias Xylenes bias Toluene Aromatic or Olefin bias Benzene Octane bias VOC Displayed Letter d x a a a a e v Maximum Bias (offset) N/A +-0.5 +-3 +-3 +-3 +-0.3 +- 3 +-5 Increment N/A +-0.1 +-.1 +-.1 +-0.1 +-0.01 +-0.1 +-1

Oxygenate biases can be set in increments of 0.1, with a maximum bias of plus or minus 0.5. Aromatic and olefin biases can be set in increments of 0.1, to a maximum of plus or minus 3.0. The benzene bias can be set in increments of 0.01, with a maximum bias of plus or minus 0.3. The RON and MON octane biases can be set in increments of 0.1 with a maximum bias of plus or minus 3.0. The offsets are stored in protected memory and are not lost if the instrument is turned off.

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8. UNIT

The UNIT function allows the user to select the format in which all oxygenate analysis results are displayed. Results can be displayed in either WEIGHT PERCENT or VOLUME PERCENT. The weight percent values are calculated using the density values selected in the DEN (4) set-up function. (see above) Total oxygen is calculated as wt% only and cannot be changed. Total aromatics, total olefins, and benzene are reported as vol. % and can not be changed. The UNIT function also allows the user to select between displaying the T50 and T90 predictions in degrees Fahrenheit or degrees Celsius. Note: GS-1000 firmware versions 2.71 and above are programmed to display the T50 and T90 temperature values in Celsius or Fahrenheit and cannot be selected in set-up.

Determining Weight Percent Oxygen


Sample weight percent oxygen is calculated using the EPA method described on page 64 of the Supplemental Notice of Proposed Guidance on Establishment of Control Periods under Section 211(m) of the Clean Air Act as Amended released in the first quarter of 1992. This method is outlined below. The following equation describes the conversion from volume percent to weight percent oxygen in a gasoline blend. wt%O= where: vol%oxy doxy wt%oxy wt%O =measured volume % of each oxygenate in the fuel =density of each oxygenate present: from table below =weight % oxygen in each oxygen present: from table below =weight % oxygen in each oxygen in the sample
FACTORS FOR CALCULATING WT% OXYGEN Component MTBE ETOH TAME ETBE MEOH DIPE TBA Gas wt%O in oxygenate 18.15 34.73 15.66 15.66 49.93 15.66 21.59 Density 0.746 0.794 0.775 0.745 0.796 0.73 0.792 0.742

(vol% oxy * d oxy * wt% oxy ) 0.742*(100 - (vol% oxy )) * d oxy )

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SECTION 7 DATA MANAGEMENT FUNCTIONS

Logging Analysis Results


The GS-1000 can store up to 99 analysis results in internal memory. After analysis results are displayed, press EXIT and select YES, when prompted, to access the log entry function. The operator will then be prompted to enter an identification code under which the analysis results will be filed.

Entering Identification Codes


Identification codes may be up to eight (8) characters long and can consist of letters and/or numbers. Numbers can be entered using the numerical keys on the keypad. Letter characters can be selected using the following procedure:

Press the up arrow key. The alphabet will appear on the top line of the display. Press the right and left arrow keys to highlight the desired letter Press ENTER to select the desired letter. Press the down arrow key.

Printing Data
Pressing PRINT (2) from the main menu will access the print functions. The GS-1000 can print either to an external printer, or to the display screen. When printing to an external printer, the printer must be connected to the instrument before the print function is selected, or an error message will appear. Be sure to remove power to the GS-1000 and the printer prior to making any connections. If power is not removed, the printer, GS instrument or both can be damaged. Upon selecting PRINT (2) from the main menu, the operator will have four choices: 1. PRINT LAST - will print the results of the last analysis performed, even if that analysis was not saved to the log. 2. PRINT LOG - will print the entire contents of the log file. 3. PRINT INDIVIDUAL - will print an individual analysis entry stored in the log. Select the desired entry by entering the identification code (see above) or by using the up and down arrows to scroll through a list of all of the stored entries. All print functions will print the data in the format selected in the set-up menu. For information on changing the print format, see Section 6: page27.

Erasing Data
The ERASE function permanently deletes entries from the log file. This function is accessed by pressing ERASE (3) from the GS-1000 main menu. Once selected, you will have two choices: ERASE INDIVIDUAL - will erase an individual analysis entry stored in the log. Select the desired entry by entering the identification code (see above) or by using the up and down arrows to scroll through a list of all of the stored entries. ERASE ALL - will erase the entire contents of the log file.

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Exporting Data
Analysis data in the log file may be downloaded as an ASCII text file from the GS-1000 to a computer using the EXPORT function, which is accessed by pressing EXPORT (5) from the main menu. Data is exported via the 9 pin RS-232 serial port located on the rear panel of the GS-1000. The port must be connected to an RS-232 serial port on an IBM compatible computer that is running any standard communication software. The host computers protocol must be set to the following:

Baud rate = 9600 bits per second Data bits = 8 Stop bits = 1 Parity = none Flow control = Xon / Xoff

When the computer is ready to accept the data file, press EXPORT LOG (1) on the GS-1000.

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SECTION 8 USER UPDATEABLE CALIBRATION

The Calibration Update Software allows the operator to add fuels to their analyzers calibration matrix without the need to return the analyzer to PetroSpec. Your GS-1000 Fuel Analyzer will notify you when a fuel that you are measuring is outside of the analyzers factory calibration matrix. (See Mahalanobis Distance and Extrapolated Results on page 25). The software allows the user to add the fuel to the calibration matrix. Please refer to the Calibration Update Manual for detailed instructions.

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SECTION 9 PRODUCT MAINTENANCE

Cleaning the GS-1000


After using the GS-1000, pump the fuel lines dry before storing the instrument. To do this, simply attach an empty bottle to the Sample Input Port and perform an analysis function. If the instrument is to be idle for more than 48 hours, it is recommended that a hydrocarbon solvent, such as petroleum ether, be used to flush the sample cell. Note: Petroleum Ether is a suitable cleaning solvent, pump dry the fuel line when completed. Fuel spills on the outside of the instrument should be wiped off as soon as possible with a clean rag. Most stains can be removed by wiping with a mild solvent.

Sample Induction Cleaning Procedure

Follow these step-by-step instructions in order to properly clean the Instruments plumbing and sample induction system. WARNING: Use protective gloves and eye protection when snapping open a PetroSpec Cleaning Solution Ampoule or Check Standard Ampoule. Be sure the area is well ventilated. Use the plastic-opening tool provided with each tray of Cleaning Solution. Follow the instructions below for safely opening the Cleaning Solution Ampoules. Be sure to keep the tool, as it is the only one provided. WARNING: When opening a Cleaning Solution Ampoule, be sure to slide the opening tool all the way onto the stem of the ampoule. The tool should bottom out on the body of the ampoule. Hold the body of the ampoule firmly in one hand. Make sure that the ampoule is in the upright position. Break the stem of the ampoule, being careful to snap it away from you. WARNING: Do not leave the Cleaning Solution Bottle Assembly unattached or unattended. The vapor pressure will cause the Cleaning Solution to flow through the supply tube. If the Cleaning Solution is not depleted during the cleaning operation, remove the Cleaning Solution Bottle Assembly Cap and recap the bottle with a normal plastic cap for storage. WARNING: It is very important that the Fuel Filter be installed correctly. If the Fuel Filter is not seated properly in the filter housing, sediment can bypass the Fuel Filter causing system blockages.

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1. Back-Flush the Instrument a. b. c. Carefully remove any waste bottles, sample bottles, and the sample tube from the Sample Inlet Port of the Instrument. Carefully remove the Brass Barbed Fitting from the Waste Outlet Port using a 5/16" Wrench or Nut Driver. Loosen the Thumb Screw at the top of the Sample Induction System, open the Fuel Filter Access Cover, and remove the Teflon Fuel Filter. Close the Cover and tighten the Thumb Screw.

Tip: If the Teflon Fuel Filter is dry it may stick to the Housing. Use a drop of fuel to wet the Filter to facilitate ease of removal d. Remove the Cap from the Cleaning Solution Bottle Assembly. Snap open a Cleaning Solution vial and pour the contents of the vial into the bottle. Screw the Cap onto the bottle and tighten.

*** See Warning A *** e. Attach the Cleaning Solution Bottle Assembly to the instrument as shown in Figure 1. Connect the Red Fitting of the Cleaning Solution Bottle Assembly to the threaded hole in the underside of the Waste Outlet Port. Connect the Quick-Connect Compressed Air Fitting on the yellow tube of the Cleaning Solution Bottle Assembly to the Quick-Connect Compressed Air Fitting on the side of the instrument. Place the Toggle Switch in the DOWN position. Connect a Waste Bottle with Drilled Cap and a Teflon Tube with Red Fitting to the Sample Inlet Port of the instrument. Press AUTO (1) on your GS or MD Series Analyzer. Allow the instrument to run through its analysis cycle. Disregard any results that are displayed. Clean the Filter Housing a. b. c. d. Unscrew the Cap of the Cleaning Solution Bottle to relieve the pressure. Loosen the Thumb Screw at the top of the Sample Induction System and open the Fuel Filter Access Cover. Thoroughly clean the inside of the Fuel Filter housing to remove any residue. Install a Teflon Fuel Filter (for Forward-Flush only).

f. g. 2.

*** See Warning C *** e. 3. a. b. Close the Fuel Filter Access Cover and tighten the Thumb Screw. Forward-Flush the Instrument Carefully remove the Waste Bottle connected to Sample Inlet Port of the instrument. Unscrew the Red Fitting on the Cleaning Solution Bottle Assembly from the Waste Outlet Port and screw it into the threaded hole in the underside of the Sample Inlet Port. See Figure 2. Connect the Waste Bottle with Drilled Cap and a Teflon Tube with Red Fitting to the Waste Outlet Port of the instrument. Press AUTO (1) on your GS or MD Series Analyzer. Allow the instrument to run through its analysis cycle. Disregard any results that may be displayed.

c. d.

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4. Repeat steps 1, 2 and 3 a. a. b. c. Repeat steps 1, 2 and 3 until the Cleaning Solution has been depleted. Be sure to return the Instrument to the normal Analysis mode set-up when finished with the Sample System Cleaning Procedure. Remove the Waste Bottle and properly dispose of its contents. Disconnect the Cleaning Solution Bottle Assembly Red Fitting from the Waste Outlet Port. *** See Warning B *** d. e. f. g. a. b. c. d. Disconnect the Quick-Connect Compressed Air Fitting on the yellow tube of the Cleaning Solution Bottle Assembly from the Fitting on the side of the Instrument. Place the Toggle Switch on the side of the Instrument in the UP position. Reinstall the Brass Barbed Fitting into the threaded hole on the underside of the Waste Outlet Port. Replace the Waste Bottle into the Waste Outlet Port. Loosen the Thumb Screw at the top of the Sample Induction System and open the Fuel Filter Access Cover. Remove any Fuel Filters used in the Sample System Cleaning procedure. Thoroughly clean the inside of the Fuel Filter housing to remove any residue. Install a new Fuel Filter in the filter housing. Be sure that the Fuel Filter seats correctly. 5. Revert to Normal set-up

6. Install a fresh Fuel Filter

*** See Warning C *** e. a. Close the Fuel Filter Access Cover and tighten the Thumb Screw. Using an empty sample bottle attached to the Sample Inlet Port and a Waste Bottle attached to the Waste Outlet Port, run one more AUTO (1) cycle to flush the system dry.

7. Flush the System Induction System dry

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Back-Flush Setup

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Forward-Flush Setup

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Replacing Fuel Filters


The Teflon fuel filter should be replaced every 50-75 samples, or at any time that it appears dirty or impairs the flow of fuel through the instrument. Replacement filters can be ordered from PAC at 281-580-0339. The model number for the replacement filters is BTGS-1420. To change the fuel filter, disconnect the fuel sample bottle from the Sample Input Port. Lift the Fuel Filter Access Cover by turning the Knurled Screw counter clockwise. Remove and discard the used filter. Inspect the o-ring located in the filter housing cap for any nicks or cuts which could cause leaks. It may be helpful to wet the filter with a drop of gasoline in order to facilitate ease of removal. Place a new Teflon filter membrane in the filter housing. Replace the Fuel Filter Access Cover and tighten the Knurled Screw by turning it clockwise. It is very important to make sure that the filter is seated properly. A poorly seated filter can allow the fuel to bypass the filter, which will result in a clog in the fuel intake path. Note: Please Note The fuel filters are shipped in tubes with 20 filters. A clear plastic separator disk separates each filter. Be careful to discard the separator. If the separator is installed in the fuel filter housing, poor fuel flow, or no fuel flow will result. Replacement filters are available from PAC Customer Service, at 281-580-0339.

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APPENDIX 1 MESSAGES

Extrapolated Result
This message indicates that the fuel sample tested does not fall within the calibration sample set. Accuracy of the stated properties may be in jeopardy. Use of the User Updateable Calibration software is recommended for fuels that present this warning. Please refer to the description of Mahalanobis Distance and extrapolated results on page 25.

Printer Fault Detected, No Connection Or Paper Feed Error


This message is displayed if the GS-1000 is unable to establish communications with an external printer when the print functions are accessed. Check that the printer is connected securely to the GS-1000 parallel printer port with a parallel printer cable. Verify that the printer has paper, is not jammed, and is on-line. If the message persists, call PetroSpec customer service.

Hydrocarbons Detected, Please Power Down


The GS-1000 contains an internal hydrocarbon sensor that detects dangerous levels of hydrocarbon vapors, either from leaks inside the instrument or in the operating atmosphere. If this message is displayed, IMMEDIATELY SHUT OFF POWER TO THE INSTRUMENT. If no fuel leaks are apparent, apply power again. If the condition persists, move the instrument to a better ventilated area and power up the instrument. If the message still persists, or if there is any evidence of a fuel leak, call PetroSpec customer service.

Chopper Wheel Failure Detected


This message indicates a malfunction of the GS-1000 optical system. Call PetroSpec customer service.

Filter Wheel Failure Detected


This message indicates a malfunction of the GS-1000 optical system. Call PetroSpec customer service.

Source Failure Detected


This message indicates a malfunction of the GS-1000 optical system. Call PetroSpec customer service.

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TABLE FORMAT PRINTOUT (DEFAULT)

GS1000 Fuel Analyzer Analysis Results

11:38:25am MeOH EtOH MTBE ETBE TAME DIPE TBA

3/19/98 = 2.1 Vol% = 1.3 Vol% = 5.0 Vol% = 0.0 Vol% = 1.4 Vol% = 0.0 Vol% = 0.0 Vol%

WEIGHT-% OXYGEN .. .26 BENZENE AROMATICS OLEFINS TOTAL XYLENES TOLUENE SATURATES RON MON R+M/2 EXPECTED R+M/2 RON ENGINE BIAS MON ENGINE BIAS DI T50 214 F T90 E200 E300 VOC Season: VOC Region: Expected RVP VOC Performance VOC =.82 Vol% = 26.1 Vol% = 12.5 Vol% = 7.8 Vol% = 5.8 Vol% = 59.8 Vol% = 93.5 = 85.1 = 89.3 = NA = 0.0 = 0.0 = 1039 = 214 F = 320 F = 43% = 85% Summer 1 10.00 = 16.6% = xxxxx mg/mile

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REPORT FORMAT PRINTOUT (SELECTABLE)


GS1000 Fuel Analyzer Analysis Date Sample NUMBER : 11:38:25am 3/19/98 : (Demonstration Data)

DESCRIPTION: _______________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ SAMPLE _______ Species ______ MeOH EtOH MTBE ETBE TAME DIPE TBA STANDARD __________ Species ______ MeOH EtOH MTBE ETB TAME DIPE TBA .26 .82 Vol% 12.5 Vol% 59.8 Vol% 26.1 Vol% 7.8 Vol% 5.8 Vol. %

Vol% ____ 2.1 1.3 5.0 0.0 1.4 0.0 0.0

Vol% ____ _______ _______ _______ _______ _______ _______ _______

WEIGHT-% OXYGEN ...

CONCENTRATION OF BENZENE ... CONCENTRATION OF OLEFINS ... CONCENTRATION OF SATURATES ... CONCENTRATION OF TOTAL AROMATICS .. CONCENTRATION OF TOTAL XYLENES CONCENTRATION OF TOLUENE OCTANE _______ MEASURED __________

EXPECTED __________ NA

OCTANE RESULT 89.3 RON 93.5 MON 85.1 RON ENGINE BIAS = 0.0 MON ENGINE BIAS = 0.0 DI T50 T90 E200 E300 VOC Season: Summer Expected Sulfur Expected RVP Total VOC VOC Reduction 1039 214 F 320 F 43% 85% VOC Region: 1 339ppm 10.0 psig 1709 mg/mile 16.6%

SIGNATURE: _________________________
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APPENDIX 2 GASOLINE SAFETY INFORMATION

Personal Protection Information


Ventilation Use adequate ventilation to control exposure below recommended levels Respiratory Protection For concentrations exceeding the recommended exposure level, use NIOSH/ MSHA approved air purifying respirator. When entering into or exiting from concentrations of unknown exposure, use NIOSH/MSHA approved self-contained breathing apparatus (SCBA). Eye Protection Use safety glasses with side shields and face shield for splash protection. Skin Protection Use gloves resistant to the materials being used (Viton, nitrile, neoprene). Use fullbody, long sleeved garments to prevent skin contact.

Handling And Storage Precautions


Do not get in eyes, on skin or clothing. Do not breathe vapors, mist, or fumes. Do not swallow. May be aspirated into lungs. Wear protective equipment and/or garments described above if exposure conditions warrant. Wash thoroughly after handling. Launder contaminated clothing before reuse. Use only with adequate ventilation. Store in a well-ventilated area. Store in tightly closed container. Bond and ground during transfer. Keep away from heat, sparks, and flames.

Reactivity Data
Stability Stable Incompatibility (Material to Avoid) Oxygen and strong oxidizing agents. Hazardous Decomposition Products Carbon oxides, lead fumes and various hydrocarbons when burned.

Health Hazard Data


Acute Effects of Overexposure
Eye May cause mild irritation, with stinging and redness of the eyes. Skin May cause mild irritation. Repeated or prolonged contact may cause defatting of the skin, resulting in dermatitis. Inhalation May cause headache, nausea, weakness, sedation, and unconsciousness Ingestion May cause irritation to intestines. If swallowed, may be aspirated resulting in inflammation and possible fluid accumulation in the lungs.

Subchronic and Chronic Effects of Overexposure


Unleaded gasoline has produced kidney cancer in male rats only. No comparable kidney disease is known to occur in humans. Gasolines generally contain benzene which has been designated a carcinogen by the National Toxicology Program (NTP), the International Agency for Research on Cancer (IARC), and the Occupational Safety and Health Administration (OSHA). Benzene may produce blood changes which include reduced platelets, red blood cells, and white blood cells. Also, aplastic anemia, and acute nonlymphotic leukemia. Benzene has produced fetal death in laboratory animals and caused chromosome changes in humans and mutation changes in cells of other organisms. Laboratory animals have exhibited a higher degree of narcosis when exposed to both butane and butylene (additive effect), than the degree of narcosis exhibited following exposure to butane or butylene alone. Isopentane did not produce kidney damage in a subchronic oral laboratory study or in a subchronic inhalation exposure to 4500 ppm and 1000 ppm or a 50/50 mixture of isobutane and isopentane.
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First Aid And Emergency Procedures


Eye Flush eyes with running water for at least fifteen minutes. If irritation or adverse symptoms develop, seek medical attention. Skin Wash skin with soap or water for at least fifteen minutes. If irritation or adverse symptoms develop, seek medical attention. Inhalation Remove from exposure. If breathing is difficult, give oxygen. If breathing ceases, administer artificial respiration followed by oxygen. Seek immediate medical attention. Ingestion Do not induce vomiting. Seek immediate medical attention.

Fire And Explosion Data


Flash point 35F (37C) Flammable Limits (% by volume in air) LEL 1.5; UEL 7.6 Fire Extinguishing Media Dry chemical, foam, or carbon dioxide (CO2) Special Fire Fighting Precautions Evacuate area of all unnecessary personnel. Wear appropriate safety equipment for fire conditions including NIOSH/MSHA self-contained breathing apparatus (SCBA). Shut off source, if possible. Water, fog or spray may be used to cool exposed containers and equipment. Do not spray water directly on fire; product will float and could re-ignite on surface of water. Fire and Explosion Hazards Carbon oxides and various hydrocarbons formed when burned. Gasolines containing Tetraethyl Lead will form lead fumes when burning. Highly flammable vapors which are heavier than air may accumulate in low areas and/or spread along ground away from handling site. Flashback along vapor trail may occur.

Spill, Leak, And Disposal Procedures


Precautions required if material is released or spilled: Evacuate area of all unnecessary personnel. Wear protective equipment and/or garments described above if conditions warrant. Shut off source, if possible, and contain spill. Protect from ignition. Keep out of water sources and sewers. Absorb in dry, inert material. Transfer to disposal drums using nonsparking equipment. Waste Disposal (Insure conformity with all applicable disposal regulations) Incinerate or otherwise manage in a RCRA permitted waste management facility.

Hazard Classification
Gasoline meets the following hazard definitions as outlined by the Occupational Safety and Health Hazard Communication Standard (29 CFR Section 1910.1200):

Flammable Liquid Health Hazard (Section F)

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PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

APPENDIX 3 WARRANTY INFORMATION

A. Limitations of Liability
PetroSpec warrants that the GS-1000 Plus VOC will be free from defects in materials and workmanship for a period of one (1) year from the date of invoice. If, during the warranty period, the product is determined by us to be defective, we and/or our representative will repair or replace the product at no cost to the purchaser. PetroSpec shall not be responsible for any expenses incurred by the user. This warranty applies only to products that are operated in accordance with PetroSpec specifications. This warranty will not apply to any product that has been subject to misuse, negligence or accident; or misapplied; or used in violation of product manuals, instructions, or warnings; or modified or repaired by unauthorized persons; or improperly installed.

B. Inspection
It is the responsibility of the purchaser to inspect the product promptly after receipt and to notify PetroSpec at its Texas office in writing of any claims, including claims of breach of warranty, within thirty (30) days of discovery of the facts upon which the claim is based. Your failure to give written notice of a claim within the time period shall be deemed to be a waiver of such claim.

C. Limitations of Remedy and Warranty


The provisions in paragraph A are our sole obligation and exclude all other remedies or warranties, expressed or implied, including warranties of merchantability and fitness for a particular purpose, whether or not purposes or specifications are described herein. We further disclaim any responsibility whatsoever to the purchaser or to any other person for injury to person or damage to or loss of property or value caused by any product which has been subjected to misuse, negligence, or accident; or misapplied; or used in violation of product manuals, instructions or warnings; or modified or repaired by unauthorized persons; or improperly installed.

D. Limitations of Damages
Under no circumstances shall PetroSpec be liable for any incidental, consequential or specific damages, losses or expenses arising from this contract or its performance in connection with the use of, or inability to use, our product for any purpose whatsoever.

E. Limitation of Actions
No action, regardless of form, arising from this contract may be commenced more than one year after the cause of action has accrued, except an action for nonpayment.

F Collateral Promises .
There are no representations, warranties, or conditions, expressed or implied, statutory or otherwise except those herein contained, and no agreement or waivers collateral hereto shall be binding on either party unless in writing and signed by the purchaser and accepted by PetroSpec at its Houston office.

G. Interpretation
Rights and liabilities arising out of any contract with PetroSpec shall be determined under the Uniform Commercial Code as enacted in Texas.

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PETROSPEC GS-1000 PLUS VOC | OPERATING M A N U A L

PETROSPEC WARRANTY REGISTRATION FORM

PetroSpec Warranty Registration Form


To assure warranty coverage of your PetroSpec Fuel Analyzer, and to allow us to keep you informed of product updates and servie advisories, please fill-in the information below and FAX to: PAC/PetroSpec at 281-580-0339 or mail to: PAC/PetroSpec, 300 Bammel Westfield Road, Houston, TX 77090

Company Name: Key Contact: Address (Location of Analyzer):

______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

Phone Number: FAX Number: Model: Serial Number: Purchased From: Purchase Date:

______________________________________________________________ ______________________________________________________________ GS-1000 Plus VOC ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

Keep a copy of this warranty for your records. Thank you for your business.

PetroSpec

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Installation Problem Report

Company: Contact: Address:

Installation Date: Installed By: PAC Representative: Sales Order #:

City: Country: Phone: E-mail: Purchase Date

St: Territory: Fax:

Zip: Fax or e-mail complete report to Service Manager fax: 281-580-0719 e-mail: service@paclp.com

S/N

Model #

Install Date

Problem(s) Model: Part #

S/N: Description of Problem

Model: Part #

S/N: Description of Problem

Model: Part #

S/N: Description of Problem

Type of Problem:

Appearance Assembly Rev. D

Broken Electric

Electronic Leak Date: 8/24/04

Missing Mechanical

Off Spec Non-function

Wrong

Code: QF 8.02

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