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Super Systems PGA 3510 Operation Manual

Portable multi-gas ir analyzer
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PGA 3510
Portable Multi-Gas IR Analyzer
(CO, CO
, and CH
Gas Analyzer
2
4
with O
and Optional H
Measurement and
2
2
% Carbon, % Dissociated Ammonia, % NH
, K
, and
3
N
K
Calculation Capabilities)
C
Operations Manual
Please read, understand, and follow these instructions before operating this equipment.
Super Systems, Inc. is not responsible for damages incurred due to a failure to comply with these
instructions. If at any time there are questions regarding the proper use of this analyzer, please contact
us at (513) 772-0060 for assistance.

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Summary of Contents for Super Systems PGA 3510

  • Page 1 Please read, understand, and follow these instructions before operating this equipment. Super Systems, Inc. is not responsible for damages incurred due to a failure to comply with these instructions. If at any time there are questions regarding the proper use of this analyzer, please contact...

  • Page 2: Pga 3510 Operations Manual

    PGA 3510 Operations Manual Super Systems Inc. USA Office Super Systems Europe Corporate Headquarters: Units 3 & 4, 17 Reddicap Trading Estate, 7205 Edington Drive Sutton Coldfield, West Midlands Shipping Address: B75 7BU 7245 Edington Drive UNITED KINGDOM Cincinnati, OH 45249...

  • Page 3: Table Of Contents

    Set User Cal / Load User Cal ........................33 Calibration Log............................33 Analog Input Calibration........................... 33 Valve Setup ..............................36 Parts List............................... 38 Warranty ............................... 39 Revision History ............................. 40 Appendix 1: PGA 3510 Common Modbus Registers................. 41 Super Systems Inc. Page 3 of 42...

  • Page 4: Introduction

    PGA 3510 Operations Manual Introduction The Model PGA 3510 (see part numbers in the Parts List on page 38) is a portable Multi-Gas IR analyzer with an Oxygen (O ) cell. It measures Carbon Monoxide (CO), Carbon Dioxide (CO ) and Natural Gas (CH typically found in an endothermic atmosphere.

  • Page 5: Specifications

    * Note: These sensors have been optimized for use at the levels normally seen in an Endothermic atmosphere. The ranges can be adjusted to fit other applications. For information regarding modifications to the ranges shown above, please contact Super Systems. Sampling method: Extraction by internal pump (when necessary) Super Systems Inc.

  • Page 6: Unpacking The Device

    PGA 3510 Operations Manual Measurement Method (CO, CO , CH Non-Dispersive Infrared (NDIR) Measurement Method (O Electrochemical Measurement Method (H Thermal Conductivity Accuracy and repeatability: ± 1% of full scale Recommended Calibration Interval: Annual Flow Meter: Inside case lid and also on-screen...

  • Page 7: Basic Operating Description

    (pens, paperclips, screwdrivers, etc.) as they can cause permanent damage to the screen and void the warranty of the instrument. After the power switch is turned on, it will take approximately 30 seconds for the PGA 3510 software to automatically load. Once the software is properly loaded, the instrument is ready to use. When the power switch is turned off, the PGA 3510 initiates a controlled shutdown procedure which takes about 15 seconds.

  • Page 8: Pump Operation

    When accessed from the main screen, the pump has two possible modes: On and Off. Carbon Calculation The PGA 3510 determines the percent carbon in the sample gas using measured amounts of CO, CO , and along with the Furnace Temperature. The Furnace Temperature is either entered by the user or obtained automatically from the Furnace Temperature Controller via RS-485 communications.

  • Page 9: Chart

    PGA 3510 Operations Manual Using infra-red analysis is considered a more accurate method for determining the percent carbon of a gas compared to using an oxygen probe alone. The single point oxygen probe assumes a theoretical mixture of endothermic gas to infer the percent carbon whereas the gas analyzer will measure the exact composition of the process gas.

  • Page 10: Chart Sub Menu

    PGA 3510 Operations Manual The right-pointing arrow with the vertical line next to it button - - will toggle between viewing the chart in or out of real-time. When in real-time mode, the chart will automatically be updated once a minute.

  • Page 11: Menu Lists

    PGA 3510 Operations Manual Pressing the red ‘X’ in the top right-hand corner of the screen will take the user back to the status screen. Menu Lists Accessing the menu screen will show three or four available options, depending on whether the Nitrider Calculation feature is installed.
  • Page 12 PGA 3510 Operations Manual To see the full range of options available, the user must use the Configuration Pass Code (Default = 2). This provides the user with all available options including calibration and setup functions. Super Systems Inc. Page 12 of 42...

  • Page 13: Carbon Calculation

    Please see the Carbon Calculation section starting on page 8. Nitrider Calculation (Available on Units Configured for Nitriding & FNC Applications) When configured for nitriding and ferritic nitrocarburizing (FNC) applications, the PGA 3510 has the ability to provide a calculation of values essential those processes—specifically, nitriding potential (K...

  • Page 14: Sessions

    CO , CO, and H 0. The PGA 3510 performs the required calculation using user-provided flow values and displays the calculated K value on the Nitrider Calculation page.
  • Page 15 PGA 3510 Operations Manual This screen will identify sessions within the date range specified at the top of the screen. As a default, sessions from the past 24 hours are shown. By expanding the data range, additional sessions can be seen.

  • Page 16: Pump Control

    PGA 3510 Operations Manual Pump Control The Pump Control screen will identify and allow the modification of the pump status (On or Off). Sensor Calibration SSi Recommends the following user calibration schedule for the PGA3510: If the device is used…...

  • Page 17: Performing A Zero Calibration

    It is good practice to begin the flow of gas before attaching the calibration gas to the instrument. This will prevent any high pressure bursts from entering the instrument. Calibration gases can be obtained from Super Systems, however they can also be obtained from any supplier of custom gases.

  • Page 18: Use Of A Co 2 Scrubber For Zero Calibrations

    To use the CO scrubber: Remove the protective caps from the scrubber and attach it to the inlet hose on the PGA 3510. The pump should then be turned on. This will pull ambient air through the scrubber and into the analyzer.

  • Page 19: Calibrating The Oxygen Sensor

    “Communications and Source Setup – Atmosphere/ Temp Sources.” The Automatic Sampling Parameters screen will allow the user to adjust the way that the PGA 3510 updates the COF / PF in the atmosphere controller. All of the parameters on this page can be disregarded if the “COF/PF Adjustment Mode”...

  • Page 20: Cof/Pf Adjustment Increment

    PGA 3510 Operations Manual COF/PF Adjustment Increment When adjustments are made automatically, this value indicates the size of the step that is made when the COF/PF is changed. It is recommended that this number remain low to avoid making sudden changes to the process that could be caused by temporary conditions.

  • Page 21: Communications And Source Setup

    Manually Setting the IP Address 1. Log in to the PGA 3510 touch screen using the supervisor access code (by default, this code is ‘2’). 2. Access the Instrument Setup → General Setup menu. 3. Select “Shut Down Software” followed by “Yes”.

  • Page 22: Atmosphere/Temp Sources

    PGA 3510 Operations Manual Atmosphere/Temp Sources RS485 communications can be set up to automatically enter and update data from the oxygen probe and, if desired, make modifications to the COF/PF in the atmosphere controller. Port Usage This is the communication method used to supply information to the instrument. The possible values are:...

  • Page 23: Port Setup

    PGA 3510 Operations Manual • SSi AC20 • SSI 9200/9205 Loop 1 • SSI 9200/9205 Loop 2 • SSI 9200/9205 Loop 3 • SSI 9100 Loop 1 • Yokogawa UDP750 • Honeywell UDC3300 • Dualpro Loop 1 Modbus • Dualpro Loop 2 Modbus Furnace Temp Instrument Address This is the address of the furnace temperature instrument.

  • Page 24: Instrument Setup

    PGA 3510 Operations Manual Instrument Setup The items shown in this menu list are settings that should only need to be changed once. Any modifications to the default values will be saved in the instrument. Calculation Factors In this menu, there are two factors that will influence the calculation of carbon: IR Shim Factor and CH Factor.
  • Page 25 This field shows the current IR Shim Factor adjustment value. It is not directly modifiable. Three Methods of %Carbon Calculation The PGA 3510 is able to calculate %Carbon using one of three methods: Default Settings, IRF Matrix, or Equipment-Specific IRF Matrices.
  • Page 26 PGA 3510 Operations Manual The following steps describe how to configure the IRF Matrix. 1. To begin, decide whether both atmosphere and temperature should be considered in setting the IR Shim Factor, or only temperature. • If both atmosphere and temperature apply, set Temp Only to “No” (and then go to step 2 below).
  • Page 27 0.3% and the temperature is 1230°, and the IRF for range set (0.25 <= Atm < 0.4, 1200 <= Temp < 1400) is 125, the PGA 3510 will set the current IR Shim Factor to 125.
  • Page 28 PGA 3510 Operations Manual 2. Open the Instrument Setup → Calculation Factors menu. 3. Open the Equipment Specific IRF Matrices menu option. Select the equipment for which you want to set up an IRF Matrix. Then click Edit. 4. IRF Matrix parameters for the selected equipment will be displayed.
  • Page 29 PGA 3510 when this option is used. Note that Use IRF Matrix and Use Furnace Temp for Furnace Setpoint must both be set to “True” for this option to work. In addition, the PGA 3510 must not be configured to communicate with slave instruments;...

  • Page 30: General Setup

    Use Furnace Temp for Furnace Setpoint When this option is set to “True”, the PGA 3510 will use the furnace temperature as the value used to select an IR Shim Factor. When this option is set to “False”, the PGA 3510 will use the temperature setpoint as the value used to select the IR Shim Factor.

  • Page 31: Other Settings

    When the dew point is enabled, it will appear near the bottom left of the Carbon Calculation screen. Language Setup The instrument language should be pre-configured at Super Systems prior to shipment but can also be changed by making a selection from the drop-down list. For the language change to take effect, the instrument must be powered off and then back on again.

  • Page 32: Tools

    Maintain Sessions The PGA 3510 is designed to delete the oldest files first in the event that the storage capacity has been exceeded. It is also possible to delete old files manually by entering a date on this screen. All files that were made before that date would be permanently deleted.

  • Page 33: Pressure Sensor Calibration

    Thermister Calibration This will be set at Super Systems and should not need to be adjusted by the end user. It allows for the sample gas temperature and the ambient temperature inside the instrument to be set. This should only be performed after the instrument has been powered on long enough for it to achieve temperature equilibrium.
  • Page 34 PGA 3510 Operations Manual IMPORTANT! SSi strongly recommends that anyone who performs these calibrations have previous experience with and strong working knowledge of this type of procedure. If in doubt, contact SSi at (513) 772- 0060 to request assistance or to have the unit returned to the factory for calibration. An improperly performed calibration will significantly impact temperature readings in a negative way.
  • Page 35 PGA 3510 Operations Manual 12. Wait for the “Current Value” displayed on the screen to get as close as possible to the voltage being delivered by the millivolt sourcing device. 13. Tap Calibrate. Tap “Yes” when asked if you want to proceed with the calibration. A progress indicator will appear.

  • Page 36: Valve Setup

    9. When the process completes, temperature calibration is finished. Valve Setup The PGA 3510 uses four flow control valves for nitriding gas analysis. These valves are enabled and set up in the Valve Setup window. Super Systems Inc.
  • Page 37 PGA 3510 Operations Manual The Valve Setup window contains the following items: A – Valve Selection Drop-Down List. Using this drop-down list, you can select the valve number ( through 4) that you want to configure. B – Valve Maximum. This field is used to set the maximum valve that can be entered for the valve gas flow.

  • Page 38: Parts List

    PGA 3510 Operations Manual Parts List The following items can be purchased as needed for the PGA 3510. Part Number Description 32012 Battery 12VDC 20623 IR Cell 31409 Cell 20624 Sensor 31274 Touch Screen Display 33018 Power Cord, AC 20634...

  • Page 39: Warranty

    Warranty Limited Warranty for Super Systems Products: The Limited Warranty applies to new Super Systems Inc. (SSI) products purchased direct from SSI or from an authorized SSI dealer by the original purchaser for normal use. SSI warrants that a covered product is free from defects in materials and workmanship, with the exceptions stated below.

  • Page 40: Revision History

    PGA 3510 Operations Manual Revision History Rev. Description Date MCO# Initial Release Please Reference MCO #2084 9/1/2011 2084 Updated for revised capability of H sensor 11/16/2012 2107 Updated for added nitriding calculations, available compatibility with 2/7/2014 2135 ammonia gas. Updated parts list. Tools menu updated as needed.

  • Page 41: Appendix 1: Pga 3510 Common Modbus Registers

    PGA 3510 Operations Manual Appendix 1: PGA 3510 Common Modbus Registers This appendix covers Modbus registers most commonly accessed by PGA 3510 users. These are Modbus registers 200 through 227 and their descriptions. There are other Modbus registers used by the PGA 3510.
  • Page 42 PGA 3510 Operations Manual Register Location Parameter Description sample_valve Sample valve state sample_control Sample valve control flow_timer Flow control base_status Status of base (0=OFF, 1=pump ON, 2=sample delay, 3=measure delay, 4=delay OFF, 5=ON) alarm_bits Alarm bit map (Bit 0=low flow, Bit...

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