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Madur GA-21 Plus Operating Manual

Flue gas analyser
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FLUE GAS ANALYSER
GA-21
Operating manual
Version: 2.1
06/2017
plus

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Summary of Contents for Madur GA-21 Plus

  • Page 1 FLUE GAS ANALYSER GA-21 plus Operating manual Version: 2.1 06/2017...

  • Page 2: Table Of Contents

    Manual GA-21Plus Index 1. Introduction..............................4 1.1. Use of this operating manual......................4 2. Maintenance...............................5 2.1. Gas sensors............................5 2.2. Gas system............................5 2.3. Battery..............................5 2.4. Service intervals..........................6 2.5. Errors during operation........................6 2.6. Switching off after use.........................6 3. General information..........................7 4. Construction..............................9 4.1. Elements of gas circuit........................9 4.1.1.
  • Page 3 5.6.3.4. Printer..........................46 5.6.3.5. Language/Country......................47 5.6.3.6. Acoustic warning.........................47 5.6.3.7. Soot (1/3)..........................47 5.6.3.8. Standard..........................47 5.6.4. Control list..........................48 5.6.5. madur Service...........................48 5.7. Storing of results..........................49 5.7.1. Storing measurement reports....................50 5.7.1.1. Report table........................51 5.7.1.2. Header (Notice) editing.......................53 5.7.1.3. Erasing reports........................54 5.7.2. Continuous storing of results....................54 5.7.2.1.

  • Page 4: Introduction

    1.1. Use of this operating manual Keep this manual with the analyser GA-21 plus, and take it with you when carry- ing out measurements. Here is a short description of the sections of this manual. 2. Maintenance This section contains important information designed to keep your analyser work- ing and to save you time and trouble.

  • Page 5: Maintenance

    Manual GA-21Plus 2. MAINTENANCE 2.1. Gas sensors The following points are important for maximising the operational life of the cells and achieving measurements without errors: do not exceed the rated concentration;  all the gas cells may react unpredictably to the presence of substances which are ...

  • Page 6: Service Intervals

    The analyser checks all circuitry continuously. Should an error become evident, then this is signalled acoustically and by the message "ERROR" on the screen. The error can be found shown on the screen MENU->OP TIONS ->madur S ERVICE -> CONTROL LIS T 2.6.

  • Page 7: General Information

    Manual GA-21Plus Warning: Certain conditions, such as strong electro-magnetic fields can cause the analyser to become "hung-up". The only solution to this problem is to switch the instrument off. It is, however, possible that the analyser will no longer react to the keyboard and can not be switched off.
  • Page 8 Manual GA-21Plus parameters the analyser calculates a variety of combustion parameters such as Stack Loss – SL, Efficiency - , Excess Air - , Loss through Incomplete Combustion – IL. The GA-21 plus also measures differential pressure.. This can be used to meas- ure the draught or pressure in the flue gas channel.

  • Page 9: Construction

    Manual GA-21Plus 4. CONSTRUCTION 4.1. Elements of gas circuit 4.1.1. Gas probe with in-line filter The gas probe is used to extract the gas under investigation and to measure its temperature. The gas probe consists of two parts, the probe pipe with thermocouple (1) and the probe holder (2).

  • Page 10: Gas Pump

    Manual GA-21Plus The plug (6) and hose quick coupler (7) are connected to the front plate of the analyser. 4.1.2. Gas pump The internal gas pump draws the gas into the GA-21 plus and passes it through the gas chambers. The self-cleaning pump is a high quality item and is known to be ex- tremely reliable.
  • Page 11 Manual GA-21Plus The toxic gases are also measured using electrochemical cells. Table 1 presents all standard gas sensors available in GA-21 plus system. Cell type Range 0-20.95 % MOX-1 0-100 % 0-20000 ppm 0-10 % 2000 ppm 0-5000 ppm...

  • Page 12: Ambient Temperature Sensor

    Manual GA-21Plus 4.2.2. Ambient temperature sensor The ambient temperature is measured by the analyser for use in some of the cal- culations carried out, such as Stack Loss. This can be carried out either by the temperat- ure compensation sensor built into the plug of the probe holder (INT) or the external con- nector T3 (EXT).
  • Page 13 Manual GA-21Plus Current and voltage inputs – top view (outputs - optional) 1 – GND 2 – I1 in 3 – U1 in 4 – I1 out GND (optional) 5 – I1 out (0/4-20mA, optional) Parameter Range -10V to +10V...

  • Page 14: Data Input/Output System

    Manual GA-21Plus Parameter Thermocouple Thermistor Range Ni-CrNi: 1 – 1300°C Pt100: 0 – 200°C Pt-RhPt: 0 – 1600°C Pt500: 0 – 500°C Fe-CuNi: 0 – 700°C Resolution 1°C 1°C 4.3. Data input/output system 4.3.1. Keyboard A film keyboard is used in the GA-21...
  • Page 15 Manual GA-21Plus Picture 2. Front elevation picture...

  • Page 16: Display

    Manual GA-21Plus 4.3.2. Display The GA-21 plus has an LCD display with graphic capabilities. To improve the read-out quality, contrast regulation for the display and backlighting are used. Measure- ment results, calculation results, diagrams, text information, menu options and others ap- pears on the display.

  • Page 17: Power Supply

    Manual GA-21Plus 4.3.5. Power supply The GA-21 plus can be used with mains power supply or be operated from the internal battery. A soot test can only be carried out when the mains supply is connected, otherwise the heating of the probe holder will not function. The mains cable is attached to the socket on the left of the keyboard.

  • Page 18: Operation

    Manual GA-21Plus 5. OPERATION 5.1. Use of the keyboard 5.1.1. Description of the keys Switches to the STORE menu Switches to the first results screen. From the current results, the use of this key switches between MEAS- URE and HOLD.

  • Page 19: Selecting Menu Options

    Manual GA-21Plus 5.1.2. Selecting menu options The menu structure is shown at the end of the manual. The various displayed menus are leading the user through the structure. The following picture shows an screen, which explains the different types of exist- ing lines.

  • Page 20: Entering Numbers

    Manual GA-21Plus 5.1.3. Entering numbers Numbers are edited as follows: digital keys enter corresponding numbers move the cursor within the line erases whole number (zero on each position) confirms and ends the entry 5.1.4. Editing text Text is edited as follows: switches the keyboard into either digital or alpha betical mode.

  • Page 21: Basic Operating Instructions

    Manual GA-21Plus ends the entering of a text (if only one line is edited - e.g. the name of a fuel) or moves the cursor down to the next line (if there are several lines in the ed ited text - e.g. the report header) end the editing of a header or footer - it enables the storage of edited text.
  • Page 22 Manual GA-21Plus The analyser does not switch to STANDBY mode if [OFF] is pressed in case: -the key is being pressed during Initial Calibration. In that case the instru ment realises the action, but will switch to STANDBY only after the cal ibration is finished.

  • Page 23: Initial Calibration

    Manual GA-21Plus 5.2.4. Initial calibration After the instrument is switched on it carries out an initial calibration for 2 minutes. Warning: Make sure the probe is not in the stack during the initial calib ration Initial calibration is of basic importance for measurement correctness and it must not be interrupted before it is finished automatically.

  • Page 24: Measurement Parameters

    Manual GA-21Plus 5.2.5. Measurement parameters Directly after the calibration is finished the option PARAMETER is displayed for control reasons or in case changes need to be done. Usually the option is selected as fol- lows: selects the MENU screen move the cursor to the PARAMETER option select the option.

  • Page 25: Fuel Selection

    Manual GA-21Plus 5.2.5.1. Fuel selection This option enables the selection of a fuel (if necessary), or the programming of a customised fuel. From PARAMETER you move to the option as follows: move the cursor to FUEL choose SELECT FUEL...
  • Page 26 Manual GA-21Plus Each fuel of this screen is defined through various parameters. To view them pro- ceed as follows: move the cursor to the desired fuel displays the fuel parameters , or gives the opor tunity to enter fuel data for the programmable fuels.

  • Page 27: Averaging Time

    Manual GA-21Plus 5.2.5.2. Averaging time To select the average time proceed as follows: move the cursor to AVERAG. TIME select Average Time edition select the time (1 to 60 ) confirm the number select min or sec confirm the selection 5.2.5.3.

  • Page 28: Boiler Parameters

    Manual GA-21Plus 5.2.5.4. Boiler parameters This option enables the user to have relevant boiler parameters printed on the Protocol printout for exact documentation. move the cursor to BOILER-PARAMETER select with YES/NO whether or not the Boiler Para- meters shall appear on the printout, respectively be-...

  • Page 29: Displaying The Measurement Results

    Manual GA-21Plus 5.3. Displaying the measurement results Select the measurement screen by pressing DATA. The measurement results are displayed on three screens, either as current values or as averaged values. 5.3.1. Current values select the first screen move backward or forward to select a screen...

  • Page 30: Averaged Values

    Manual GA-21Plus switches between AVERAGED VALUES and CUR- RENT VALUES switches On/Off the HOLD function ("freezing" the current values ) 5.3.2. Averaged values Select desired averaging time as described in section 5.2.5.2. select the screen. The title line has to read AVER-...

  • Page 31: The Averaging Process

    Manual GA-21Plus 5.3.3. The averaging process The analyser is capable to display all results, measured or calculated, either as current value or as averaged value. The averaging time can be selected in a range of 10 seconds to 60 minutes. If a time of 1 min was set, the averaged results over that time would be shown on the display.

  • Page 32: Pressure/Draft Measurements

    GA-21Plus 5.4. Pressure/Draft measurements It is possible to measure differential pressure with the GA-21 plus. To do so the stubs PRESSURE (-) and (+) on the front plate are used. The measurement is performed as follows: select the main MENU move the cursor to PRESSURE select the option.

  • Page 33: Soot (Smoke) Measurement

    Manual GA-21Plus 5.5. Soot (smoke) Measurement To perform a soot test it is essential to prevent the flue gas from condensing on the filter. Therefore it is necessary to use a heated probe holder. It is only possible to per- form a soot test if the instrument is connected to the mains.

  • Page 34: Options

    Manual GA-21Plus stops the soot test After the soot test the filter is compared with a scale, and the evaluated soot num- ber is entered. enter the detected soot number confirm the soot number The stored soot number remains stored until a new one is entered, or either a printout of the measured values is performed, or they are stored in a report.

  • Page 35: Device Info

    Manual GA-21Plus 5.6.1. Device info move the cursor to DEVICE INFO select option The DEVICE INFO screen shows the serial no. of the instrument, the date of the last service, the operating time, the time until the next service, the speed of the sucked flue gas , the battery charge, the battery capacity and whether or not the communication with the madCom PC software is locked.

  • Page 36: Sensors

    Manual GA-21Plus 5.6.2. Sensors Select the option SENSORS from the screen OPTIONS as follows: move the cursor to SENSORS select the option. The following screen appears 5.6.2.1. Sensor CO (only in dual CO sensor configuration) In dual CO sensor configuration there is possibility to select working mode: -Auto –...

  • Page 37: Co Range

    Manual GA-21Plus 5.6.2.2. CO range If the concentration of CO in the gas stream exceeds the limit set here, then the cell is automatically purged with fresh air. This limit can be altered as follows: move cursor to the line CO RANGE...

  • Page 38: External Channels

    Manual GA-21Plus 5.6.2.4. External channels Get from the screen SENSORS to the option EXTERNAL CHANNELS as fol- lows: move the cursor to EXTERNAL CHANNELS select option move the cursor to the line to be changed change the setting: TH GAS Gas temperature sensor –...
  • Page 39 Manual GA-21Plus T3/T4 EXT - External resistance thermometer - Select the desired temper- ature sensor. The input T3 EXT can be defined as a Pt100, Pt500 or KTY-2k thermistor. U/I1 EXT External Voltage/Current input - Select the desired input sig- nal .

  • Page 40: Sensor Calibration

    Manual GA-21Plus 5.6.2.5. Sensor calibration Except for O2 every electrochemical sensor needs to be calibrated with calibra- tion gas. To calibrate the sensors they are fed one by one with calibration gas of a known concentration. After a few minutes the sensor supplies a stabilised signal which can be stored as calibration value.
  • Page 41 Manual GA-21Plus move the cursor to the sensor to be calibrated select the gas type Calibration screen will appear: All currently installed electrochemical sensors are visible in this screen The individual rows have the following meanings: Cell – Sensor type Signal –...

  • Page 42: Calibration Adjustment

    Manual GA-21Plus in the GAS line. Confirm standard gas editing. Sup- ply the instrument with standard gas for about 4 min. in the STORE line, as soon as the value has stabil- ised, stores the measured value as calibration value.

  • Page 43: Settings

    Manual GA-21Plus Apply reference mixture for few minutes and allow the signals to stabilise. Finish the adjustment by pressing * ADJUST * button. Adjustment is remembered, even after powering ON/OFF the analyser! To re- move this calibration adjustment, one need to manually perform REMOVE ADJUST- MENT.
  • Page 44 Manual GA-21Plus...

  • Page 45: Clock

    Manual GA-21Plus 5.6.3.3. Clock This option allows the internal clock to be adjusted. move the cursor to CLOCK select option move the cursor to desired line opens editing set date and time. They are entered in the sequence TIME - HH:MM.SS and DATE as given by the format line below.

  • Page 46: Printer

    Manual GA-21Plus 5.6.3.4. Printer This option allows the printer (printout) settings to be defined. move the cursor to PRINTER SETTINGS select option SHORTFORM switches between YES/NO. If the option is activ- ated, then a print-out of the current values will show only the volume concentrations of the gases, not the mass concentrations in mg/m³.

  • Page 47: Language/Country

    Manual GA-21Plus 5.6.3.5. Language/Country The instrument enables the user to select between languages. move the cursor to LANGUAGE confirms the selection select language confirms the language 5.6.3.6. Acoustic warning enables/deisables acoustic warning 5.6.3.7. Soot (1/3) 5.6.3.8. Standard sets the instrument to default settings...

  • Page 48: Control List

    (OK), or which is defective (*E*). move the cursor to CONTROL LIST select option 5.6.5. madur Service This option is for service engineers only. A code is needed to enter the menu - exit with [MENU] key.

  • Page 49: Storing Of Results

    Manual GA-21Plus 5.7. Storing of results Since the measured results can be stored in the EEPROM memory, it is possible to read them out later for treatment using the madCom software. Data can be stored in two separate forms. Up to 30 measurement reports and up to 10 banks from continuous measurements containing a total of 1024 sets of results.

  • Page 50: Storing Measurement Reports

    Manual GA-21Plus 5.7.1. Storing measurement reports The measurement report contains all the results obtained in a single measure- ment. It contains either current or averaged values and other user-defined factors such as fuel, footer, header etc. If the report should contain soot measurement results or pressure data, then these measurements must be carried out before storing the report.

  • Page 51: Report Table

    Manual GA-21Plus 5.7.1.1. Report table This option allows one to view, print and erase Report contents. move the cursor to REPORTS TABLE select option Reports without [♦] are empty. erases the selected Reports shows the selected Reports, the following screen...
  • Page 52 Manual GA-21Plus...

  • Page 53: Header (Notice) Editing

    Manual GA-21Plus 5.7.1.2. Header (Notice) editing This option allows to edit a notice which can be stored and printed with a Report. The HEADER may have 4 lines of 20 characters. Measurement site and/or short description of the site are commonly stored in such notes.

  • Page 54: Erasing Reports

    Manual GA-21Plus 5.7.1.3. Erasing reports All protocols can be erased in that option. move the cursor to DELETE ALL REPORTS select option leaves the screen without erasing the Reports erases all reports 5.7.2. Continuous storing of results This type of storing involves the continuous storing of a set of up to 10 measure- ment results (ONE BLOCK) during a measurement session.
  • Page 55 Manual GA-21Plus Starting the continuous storing of results ( in Banks ) call the STORE menu check whether enough free memory is available for the measurement. If not, one or more banks must be erased. The option DELETE ALL BANKS can be used.

  • Page 56: Banks Table

    Manual GA-21Plus storage is stopped, the word ACTIVE disappears 5.7.2.1. Banks table The option BANKS TABLE provides information about the stored Banks. move the cursor to the option BANKS TABLE select the option BANKS TABLE. The last bank can be erased in the BANKS TABLE screen (the Bank must not be...

  • Page 57: Data-Logger

    Manual GA-21Plus 5.7.3. Data-logger GA-21plus analyser can be optionally equipped with data-logger. Such device has additional microSD card slot, located beneath the printer cover. Data-lgger options are available from Store menu: To use data-loger, insert SD card to the slot and, if necessary, format it from analyser’s menu.
  • Page 58 Manual GA-21Plus 5. Boiler parameters When all is set, execute 3-XL by pressing ***** START **** - analyser will perform test ac- cording to the set averaging time. Each test will start immediately after previous one has ended. Currently performed test is indicated with its number in top left corner. Results presented on screen are for the previous period, i.e.

  • Page 59: Printer

    Manual GA-21Plus 5.9. Printer 5.9.1. Printing the contents of a screen This is not possible for the screen (D1). A screen may not be printed whilst data is being entered using the alphanumeric keyboard until this activity has been ended.
  • Page 60 Manual GA-21Plus...

  • Page 61: Gas Block Diagram

    Manual GA-21Plus 6. GAS BLOCK DIAGRAM 1. Gas inlet 2. Filter 3. Main gas pump 4. Flow control sensor 5. Pressure sensor 6. Electrochemical cells in the main gas channel 7. Check valve 8. Purging pump 9. Electrochemical cell in the secondary gas channel 10.

  • Page 62: Menu Structure

    Manual GA-21Plus 7. MENU STRUCTURE 7.1. Structure of the main menu MAIN Parameter Fuel selection Choose fuel View/define Average time Boiler data Pressure Pressure Soot test Soot test Options Device info. View data Sensors CO range O2 cell calibr.

  • Page 63: Structure Of The Menu Store

    Manual GA-21Plus 7.2. Structure of the menu STORE STORE Reports Save Report No. Reports Table View Report Header Editing Edit Banks Activate/Lock List of Banks View List Delete All Reports Erase All Delete All Banks Erase All...

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