GE Sensing CGA 351 Operating Manual

Measurement & Control Oxygen Analysis

CGA 351

Zirconium Oxide Oxygen Analyzer

User’s Manual

910-199 Rev. E

May 2013

CGA 351

Zirconium Oxide Oxygen Analyzer

User’s Manual

910-199 Rev. E May 2013

ge-mcs.com

Technical content subject to change without notice.

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Preface

Information Paragraphs

Note paragraphs provide information that provides a deeper understanding of the situation, but is not essential to

•

the proper completion of the instructions.

• Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the

equipment. Failure to follow these instructions carefully may cause unreliable performance.

• Caution! paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to

property or equipment.

• Warning! paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to

personnel. Cautionary information is also included, when applicable.

Safety Issues

WARNING! It is the responsibility of the user to make sure all local, county, state and national codes,

regulations, rules and laws related to safety and safe operating conditions are met for each installation.

Auxiliary Equipment

Local Safety Standards

The user must make sure that he operates all auxiliary equipment in accordance with local codes, standards, regulations, or laws applicable to safety.

Working Area

WARNING! Auxiliary equipment may have both manual and automatic modes of operation. As equipment

can move suddenly and without warning, do not enter the work cell of this equipment during automatic operation, and do not enter the work envelope of this equipment during manual operation. If you do, serious injury can result.

WARNING! Make sure that power to the auxiliary equipment is turned OFF and locked out before you

perform maintenance procedures on the equipment.

Qualification of Personnel

Make sure that all personnel have manufacturer-approved training applicable to the auxiliary equipment.

Personal Safety Equipment

Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment. Examples include safety glasses, protective headgear, safety shoes, etc.

Unauthorized Operation

Make sure that unauthorized personnel cannot gain access to the operation of the equipment.

CGA 351 User’s Manual iii

Preface

Environmental Compliance

Waste Electrical and Electronic Equipment (WEEE) Directive

GE Measurement & Control Solutions is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE) take-back initiative, directive 2002/96/EC.

The equipment that you bought has required the extraction and use of natural resources for its production. It may contain hazardous substances that could impact health and the environment.

In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or recycle most of the materials of your end life equipment in a sound way.

The crossed-out wheeled bin symbol invites you to use those systems.

If you need more information on the collection, reuse and recycling systems, please contact your local or regional waste administration.

Visit http://www.ge-mcs.com/en/about-us/environmental-health-and-safety/1741-weee-req.html take-back instructions and more information about this initiative.

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iv CGA 351 User’s Manual

Contents

Chapter 1. General Information

1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 The Sensor Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1.3 The Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.4 Principles of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.5 The Zirconium Oxide Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.6 The Heater Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 2. Installation

2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.2 Choosing an Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.3 Mounting the CGA 351. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.4 Connecting the Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.5 Wiring the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.5.1 Wiring the Outputs (TB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.2 Wiring the Inputs (TB2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.3 Wiring the Line Power (TB3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Chapter 3. Operation

3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3.2 Preventing Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3.3 Powering Up the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.4 User Program Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.5 Configuring the Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.5.1 Initial Screen Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.5.2 Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3.5.3 Using the Auto Range Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.5.4 Configuring the Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.5.5 Configuring the Analog Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

3.5.6 Switching Display Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

3.6 Converting mV to Oxygen Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3.7 Powering Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

CGA 351 User’s Manual v

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Chapter 4. Setup and Calibration

4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.2 Accessing the User Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.3 The [Cal] Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.4 Setting Up the Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.4.1 Setting the Trip Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4.4.2 Setting the Trip Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

4.4.3 Setting the Deadband Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

4.4.4 Testing the Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

4.4.5 Selecting the Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

4.5 Setting the Temperature Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

4.5.1 Entering the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

4.5.2 Entering the Sensor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

4.5.3 Setting the Air Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

4.5.4 Selecting the Gas Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

4.5.5 Selecting the Proportional Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

4.5.6 Setting the Integration Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

4.5.7 Setting the Maximum Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4.5.8 Restoring the Default Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

4.6 Auto Range Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

4.6.1 Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

4.6.2 Programming the Auto Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

4.7 The [Opt-User] Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

4.8 Setting Fault Alarm Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.9 Setting Up the Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

4.9.1 Selecting the Analog Output Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

4.9.2 Setting the Zero Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

4.9.3 Setting the Span Setpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

4.9.4 Testing the Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

4.9.5 Setting the Zero Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

4.9.6 Setting the Span Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.10 Adjusting the Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

4.11 Setting the Display Backlight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

4.12 Setting Up the Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.12.1 Entering the Node ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.12.2 Entering the Baud Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

4.12.3 Entering the Number of Data Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.12.4 Entering the Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

4.12.5 Entering the Number of Stop Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

4.12.6 Selecting the Type of Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

4.13 Setup and Security Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

4.13.1 Setting Up the Option Card Slots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

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4.13.2 Setting the Security Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

4.14 Calibrating the CGA 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

4.14.1 Recommended Calibration Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

4.14.2 Regulating the Calibration Gas Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

4.14.3 Adjusting the Calibration Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

4.15 Checking the Current Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

4.15.1 Checking the Sensor Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

4.15.2 Viewing the Heater Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Chapter 5. Service and Maintenance

5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

5.2 General Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

5.2.1 Checking the Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

5.2.2 Checking the Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

5.2.3 Checking the Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

5.2.4 Checking the Sensor Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

5.2.5 Checking the Sensor Furnace Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

5.3 Oxygen Measurement Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

5.3.1 Oxygen Concentration Reads Constant 20.93%. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

5.3.2 Oxygen Reading Above 100%. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

5.3.3 Oxygen Reading Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

5.3.4 Oxygen Reading Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

5.4 Calibration Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

5.4.1 Everything Is Fine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

5.4.2 Forced Flow Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

5.4.3 Plugging or Dead Space Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

5.5 Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

5.5.1 The Sensor Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

5.5.2 The Electronics Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

5.6 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Chapter 6. Specifications

6.1 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

6.2 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

6.3 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Appendix A. The Nernst Equation

A.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

A.2 Equilibrium Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

A.3 The CGA 351 Nernst Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

CGA 351 User’s Manual vii

Contents

Appendix B. CE Mark Compliance

B.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

B.2 EMC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

B.3 LVD Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Appendix C. Optional Enclosures

C.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

C.2 Rack Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

C.2.1 Mounting the Rack Mount CGA 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

C.2.2 Connecting the Sample System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

C.2.3 Wiring the Rack Mount CGA 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

C.3 Rack Mount Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

C.4 Rack Mount Service and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

C.4.1 Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

C.4.2 Replacing the Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

viii CGA 351 User’s Manual

Chapter 1. General Information

1.1 Introduction

The CGA 351 monitors the oxygen content of any clean and dry gas stream. The analyzer can accurately measure oxygen levels from 0.1 ppm to 100% O

accomplished with a precision, temperature-controlled, zirconium oxide (zirconia) oxygen sensor.

The standard CGA 351 analyzer, as shown in Figure 1 below , is supplied in a pair of stainless steel enclosures mounted side-by-side on a metal plate with a 40” flexible conduit connecting the two. This compact, wall-mounted system includes the following components:

• A sensor enclosure, which contains the oxygen sensor, sensor furnace, thermocouple, inlet port with needle

valve, outlet port with flowmeter, and interconnecting cable(s), and

• An electronics enclosure, which contains the temperature control circuitry, output signal processing circuitry,

digital display, user interface, and wiring terminal strips.

The CGA 351 analyzer is also available in optional enclosures (see Appendix C for more information).

, and can even measure oxygen content in reducing gases. This is

Figure 1: Standard CGA 351 Analyzer

CGA 351 User’s Manual 1

Chapter 1. General Information

Furnace Bracket

Flowmeter

Thermocouple

Needle Valve

Sensor Furnace

Oxygen Sensor

Manifold

Electrical Conduit

1.2 The Sensor Enclosure

The sensor enclosure, which is shown in Figure 4 below, houses the sample measurement components. The functions of these components are as follows:

• A zirconium oxide (zirconia) oxygen sensor converts the oxygen concentration of the sample gas into a mV

output signal.

• A sensor furnace heats the oxygen sensor and the sample gas to the optimum temperature of 700°C.

• A thermocouple precisely regulates the temperature of the oxygen sensor and the sample gas.

• An inlet needle valve and an outlet flowmeter adjust the sample gas flow to 400 ± 40 cc/min.

2 CGA 351 User’s Manual

Figure 2: Sensor Enclosure

Chapter 1. General Information

SAMPLE

INLET

SAMPLE OUTLET

INLET

CAL-GAS

INPUTOUTPUT

To: CGA 351 Inlet

From: CGA 351 Outlet

1.3 The Sample System

In addition to the components supplied with the CGA 351, an external sample system may be required to ensure that the analyzer is fed a properly conditioned sample or calibration gas stream. In particular, the gas must be clean and dry, and it must be delivered to the analyzer at atmospheric pressure.

Note: A suitable sample system, which will be supplied completely assembled on its own mounting plate, may be

ordered directly from GE. Commonly used sample system components include filters, pressure regulators, pressur e gauges, by-pass loops, and sample pumps. It is recommended that stainless steel construction be used for all wetted parts of the sample system. A typical sample system is shown in Figure 3 below.

Figure 3: Typical Sample System

CGA 351 User’s Manual 3

Chapter 1. General Information

1.4 Principles of Operation

A gas sample is drawn into the inlet port of the analyzer by gas diffusion and a forced flow determined by the external sample system. The sample gas then flows through a ceramic inlet tube and into the annular space between the inlet tube and the inside of the zirconium oxide oxygen sensor. The flowmeter on the outlet port and the needle valv e on the inlet port are used to adjust the sample flow rate to 400 ± 40 cc/min.

In the annular sample space, the gas is heated to the same 700°C at which the zirconium oxide oxygen sensor is maintained. A mV signal is generated. This signal is proportional to the logarithm of the ratio of the oxygen concentration in the sample gas to the oxygen concentration in a reference gas contacting the outer electrode. In the display electronics, the logarithmic signal can be read directly in unlinearized form, or it can be converted to a 0/4–20 mA, 0–2 V, or Namur linearized signal before display.

Note: A temperature above 650°C is required for proper operation of the oxygen sensor. Also, ambient air is the

usual reference gas on the outside of the zirconium oxide sensor.

The sensor furnace also generates the convective flow that circulates the sample gas through the sample path. Pushed from behind by the hot gases still in the furnace, the hot sample gas in the sensor furnace rises out of the furnace and cools. The cooled sample gases then pass through the outlet port, where they are carried away by the main gas flow.

A platinum coating on the end of the ceramic tube and the zirconium oxide oxygen sensor ensures that all oxidation/reduction reactions in the sample gas reach equilibrium. It is therefore possible to measure such parameters as excess oxygen in air/fuel mixtures and equilibrium oxygen in reducing atmospheres such as hydrogen.

4 CGA 351 User’s Manual

Chapter 1. General Information

Volts

Sample O

Inside Cell

Oxygen ions migrate through the zirconium oxide along the concentration gradient.

From Outside

Electrode

From Inside Electrode

Zirconium Oxide Ceramic with Lattice Imperfections

Atmospheric O

Outside Cell

When O concentration in sample gas falls, the cell voltage rises

with increased oxygen migration through the zirconium oxide.

1.5 The Zirconium Oxide Oxygen Sensor

The inside and outside of the zirconium oxide oxygen sensor are coat ed wit h porou s plat inum, forming two electrodes. The sample gas flows past the inside of the sensor, while atmospheric air circulates freely on the outside of the sensor. This atmospheric air is used as the reference gas for making oxygen measurements (see Figure 4 below).

At the operating temperature of the oxygen sensor, the atmospheric reference oxygen is electrochemically reduced at

Figure 4: Oxygen Migration in the Zirconium Oxide Sensor

the outer electrode, and the resulting oxygen ions seek to equalize with the lower oxygen concentration on the sample side of the cell by migrating through the porous ceramic toward the inner electrode. At the inner electrode they give up electrons to become oxygen molecules again, and are swept away by the sample flow.

The lower the concentration of oxygen in the sample gas, the greater the rate of ion migration through the ceramic, and the higher the cell voltage due to electron exchange at the electrodes. The cell voltage rises logarithmically as the amount of oxygen in the sample gas falls, allowing the accurate measurement of very low levels of excess oxygen.

CGA 351 User’s Manual 5

Chapter 1. General Information

1.6 The Heater Control Circuit

The oxygen sensor temperature in the CGA 351 is maintained by a heater, which is part of a complex temperature control loop. This circuit constantly monitors the temperature input from an RTD, compares it to the set point temperature, and turns the heater ON or OFF accordingly. The specific type of control circuit, a Proportional Integral Derivative (PID) loop, is used because of the adjustable parameters involved:

• Proportional Band: Because the system cannot respond instantaneously to temperature changes, the actual

temperature of the oxygen sensor oscillates about the set point. In general, increasing the proportional band reduces the magnitude of these temperature oscillations.

• Integral Action: A consequence of increasing the proportional band is the introduction of an offset between

the set point and the control point. The integral portion of the control loop acts to move the control point back toward the set point within a specified period of time. Decreasing this integration time reduces the offset more quickly.

Note: A third parameter, Derivative Action, is not used with the CGA 351.

The heater control circuit is configured at the factory for optimum performance. Because of the strong interaction between the parameters involved, properly setting up the PID loop is a very complex matter. As a result, randomly changing the P or I parameters can seriously degrade the performance of the CGA 351.

IMPORTANT: Always contact GE before attempting to change the default P or I values. The submenu for performing

these changes is password protected to prevent accidental changes.

6 CGA 351 User’s Manual

Chapter 2. Installation

2.1 Introduction

This chapter provides a general description of the standard CGA 351 and gives directions on how to install and wire the analyzer for proper operation.

Note: For information regarding component locations and/or wiring connections in an optional enclosure, see

Appendix C.

IMPORTANT: For compliance with the European Union’s Low Voltage Directive (2006/95/EC), the CGA 351 requires

an external power disconnect device such as a switch or circuit breaker. The disconnect device must be marked as such, clearly visible, directly accessible, and located within 1.8 m (6 ft) of the unit.

WARNING! Power up the CGA 351 as quickly as possible after introduction of the sample gas. If the analyzer

is left installed without power, the unit’s components become susceptible to acid condensation that will cause corrosion.

Be sure to observe all installation limits and precautions described in this chapter. Pay particular attention to the ambient temperature range of –25 to +50°C (–13 to +122°F) specified for the instrument.

WARNING! To ensure safe operation of the CGA 351, the unit must be installed and operated as described in

this manual. Also, be sure to follow all applicable local safety codes and regulations for installing electrical equipment. In addition, all procedures should be performed by trained service personnel.

2.2 Choosing an Installation Site

All environmental and installation factors should have been discussed with a GE application engineer or field sales person at the time the CGA 351 was ordered. Thus, the equipment should be suited to the application and the planned installation site. Before installing the unit, however , read the following guidelines to verify that the best installation site has been chosen for optimum instrument accuracy and reliability. Make sure that:

• The CGA 351 enclosures are suitable for the environmental conditions at the installation site.

• The analyzer system will be installed in a location with little or no vibration.

• The ambient temperature at the installation site is between –25° and 50°C (–13° and 122 °F ) .

• There are no restrictions in the discharge line (i.e. flow control valves downstream of the meter).

• The CGA 351 system is installed in a location that provides ready access for programming, testing, and

servicing the unit.

• The cables will be protected from excessive physical strain (bending, pulling, twisting, etc.). Do not subject the

cables to temperatures above 65°C (149°F) or below –50°C (–58°F).

• The line voltage used at the planned installation site corresponds to the factory preset line voltage rating for the

meter.

CGA 351 User’s Manual 7

Chapter 2. Installation

2.3 Mounting the CGA 351

This section explains how to mount the analyzer components at the installation site and how to connect the sample system to the analyzer.

Note: If more than one analyzer system is being installed, be aware that each system is a matched set (i.e., each

sensor enclosure must enclosures to match the systems correctly.

IMPORTANT: For compliance with the European Union’s Low Voltage Directive (2006/95 /EC), th e CGA 351 requires

IMPORTANT: This symbol indicates Caution - risk of electric shock:

Refer to Figure 5 on page 13, and complete the following steps to mount the CGA 351:

1. Select a flat surface on a vertical wall or instrument panel with sufficient space to hold the mounting plate with

both of the CGA 351 enclosures.

Note: Mount the system in an upright position, so that the sample inlet and outlet fittings are on the bottom of the

sensor enclosure.

be matched to a specific electronics enclosure). Refer to the identification tags on the

2. Using the mounting dimensions shown in Figure 5 on page 13, locate and prepare four (4) mounting holes or two

(2) horizontal mounting rails on the vertical surface.

3. Secure the system to the mounting surface with four (4) sets of mounting hardware. Be sure that the enclosures are

in a vertical position, with the inlet/outlet connectors on the bottom.

4. The flowmeter, which is fastened to the right side of the sensor enclosure, is connected to the discharge port on the

bottom of the unit with a length of 6mm stainless steel tubing. Make sure that the factory-installed Swagelok fittings are secure.

5. A flow control valve is attached to the inlet port on the bottom of the sensor enclosure with 6mm stainless steel

tubing and Swagelok fittings. Point the valve in the proper direction to receive the inlet piping from the sample system, and securely tighten the fittings.

2.4 Connecting the Sample System

The sample system should be located so that it is able to deliver a sample at a flow rate of 400 ±40 cc/min. For best results, mount the sample system as close as possible to the CGA 351. An ideal location would be on the same panel, just below the analyzer. If there are questions, consult with an applications engineer at the factory.

See Figure 5 on page 13, and complete the following steps to connect the sample system to the analyzer:

1. Using 6mm stainless steel tubing (or ¼” stainless steel tubing with adaptors), connect the gas source from the

sample system to the Swagelok fitting on the flow control valve at the inlet port on the analyzer.

2. Using 6 mm stainless steel tubing (or ¼” stainless steel tubing with adaptors), connect the Swagelok outlet fitting

at the top of the flowmeter on the analyzer to the gas discharge connection on the sample system.

Note: If desired, a suitable sample system may be ordered directly from the factory. The sample system would be

supplied fully assembled on a flat plate with four (4) mounting holes.

8 CGA 351 User’s Manual

Chapter 2. Installation

2.5 Wiring the Analyzer

The system components which are housed in the sensor enclosure have already been wired at the factory. These include:

• Oxygen sensor (TB2)

• Thermocouple (TB2)

• Sensor furnace (TB2)

To completely wire the CGA 351 zirconium oxide oxygen analyzer, the following items must be connected:

• Serial port (TB1)

• Analog output (TB1)

• Alarm relays (TB1)

• Line power (TB3)

Refer to the wiring diagram shown in Figure 6 on page 14, while completing the instructions in this section.

WARNING! In order to meet CE Mark requirements, all cables must installed as described in Appendix B, CE

Mark Compliance.

IMPORTANT: For compliance with the European Union’s Low Voltage Directive (2006/95/EC), the CGA 351 requires

WARNING! To ensure safe operation of the CGA 351, the unit must be installed and operated as described in

To access the terminal printed circuit board, remove the cover below the digital display panel, which is fastened with six (6) Phillips head screws. The PC Board has terminal blocks TB1 (12 connections), TB2 (8 connections), and TB3 (3 connections) mounted on it. Proceed to the appropriate sub-section to wire each of these terminal blocks.

CGA 351 User’s Manual 9

Chapter 2. Installation

2.5.1 Wiring the Outputs (TB1)

Terminal block TB1 contains connections for the CGA 351’s output signals. Specifically, the following signals are available at this terminal block:

• Serial port

• 0/4–20 mA, 0–2 V, or Namur analog output

• Alarm relays

To wire any or all of these output signals, complete the following steps:

1. Attach a cable or conduit with the appropriate number of conductors to an entry port on the bottom of the

electronics enclosure.

2. To connect a serial port from a personal computer, use the COMM pins on terminal block TB1 as follows:

a. Connect the transmit wire to pin b. Connect the receive wire to pin c. Connect the ground/return wire to pin

2. C.

3. To connect an analog output device, use the 4-20mA pins on terminal block TB1 as follows: a. Connect the input wire to the external device to pin b. Connect the output wire from the external device to pin

–.

4. To connect alarm device(s), use the ALARM 1 and/or ALARM 2 pins on terminal block TB1 as follows: a. Connect the input wire to the alarm-1 device to pin b. Connect the output wire from the alarm-1 device to pin

NO.

c. If desired, repeat sub-steps a and b to connect alarm-2.

5. Connect any shields to pin

Proceed to the next section to continue wiring the CGA 351.

10 CGA 351 User’s Manual

Chapter 2. Installation

2.5.2 Wiring the Inputs (TB2)

Terminal block TB2 contains connections for the CGA 351’s sample measurement signals. Specifically, the following signals are routed to this terminal block:

• Zirconium oxide oxygen sensor

• Thermocouple

• Sensor furnace

All of the connections on terminal block TB2 have already been wired at the factory. In the event that one or more of these wires must be reconnected, complete the following steps:

1. Locate the leads from the zirconium oxide oxygen sensor. Connect these leads to terminal block TB2 as follows:

a. Connect the positive sensor wire (white - #1) to pin b. Connect the negative sensor wire (white - #2) to pin

–.

2. Locate the leads from the thermocouple. Connect these leads to terminal block TB2 as follows:

a. Connect the positive thermocouple wire (yellow - no number) to pin b. Connect the negative thermocouple wire (red - no number) to pin

–.

Note: The two thermocouple wires (red and yellow) are bound together in a brown sheath.

3. Locate the leads from the sensor furnace. Connect these leads to terminal block TB2 as follows:

a. Connect one furnace wire (white - #5) to pin b. Connect the other furnace wire (white - #6) to pin

Note: The polarity of the sensor furnace leads is not important.

4. Connect the ground wire (white - #G) and any shields to either of the pins labeled

This completes the wiring of terminal block TB2. Proceed to the next section to continue wiring the CGA 351.

CGA 351 User’s Manual 11

Chapter 2. Installation

2.5.3 Wiring the Line Power (TB3)

Terminal block TB3 contains connections for the line power to the CGA 351. To wire the line power, complete the following steps:

WARNING! Before proceeding with the section, verify that the line power has been turned off at the external

disconnect device.

1. Attach a cable or conduit with the three line power conductors to an entry port on the bottom of the electronics enclosure.

CAUTION! Be sure that the input voltage to the CGA 351 complies with the value specified at the time of

purchase. If the voltage is incorrect, contact the factory immediately.

2. Connect the line power leads to terminal block TB3 as follows: a. Connect the line power lead (black) to pin b. Connect the neutral power lead (white) to pin

c. Connect the ground power lead (green) to the protective earth ground post, identified by .

This completes the wiring of the CGA 351 analyzer. Proceed to Chapter 3, Operation, for instructions on using the analyzer.

12 CGA 351 User’s Manual

Chapter 1. Installation

(406)

11 1/2

(292)

9 1/2

(241)

3 1/2

(89)

6 3/4 (171)

7 3/8 (187)

6 3/8 (162)

SIDE VIEW

FRONT VIEW

(406)

14 1/4

(362)

7/8 (22)

8 1/4 (208)

3 7/8 (98)15 1/4 (387)

17 (432)

Ø1/2 (Ø12.7) 4pl

Mounting Hole

Mounting

Note: Dimensions are in inches (millimeters).

Plate

Figure 5: CGA 351 Mounting Dimensions

CGA 351 User’s Manual 13

FUSE

TB3

TB2

TB1

COMM 4-20mA ALARM 1 ALARM 2 O2 TC HEATER 90-265 VAC

Group

COMM

4-20mA

ALARM 1

ALARM 2

Pin #

ALL

Description

RS232 Transmit (TX)

RS232 Receive (RX)

RS232 Return (RTN)

Any Shield or Ground

Analog Output (SIG+)

Analog Output (SIG-)

Normally Open (Standard Mode)

Common

Normally Closed (Failsafe Mode)

Normally Open (Standard Mode)

Common

Normally Closed (Failsafe Mode)

TB1 - OUTPUTS

HEATER

Thermocouple (-)

Furnace (+)

Any Gnd/Shield

Furnace (-)

Any Gnd/Sh

ield

Thermocouple (+)

Group

Description

TB2 - INPUTS

Pin #

Sensor (-)

Sensor (+)

ALL

6 (White)

5 (White)

N.A.

G (White)

N.A. (Red)

N.A.(Yellow)

2 (White)

1 (White)

Wire # (Color)

TB3 - POWER*

Pin #

5 x 20 mm

Size:

4 A, 250 V

FUSE

Type:

Rating:

TD (Time-Delay)

*90-265 VAC, 50/60 Hz, 900 W

NOTE: For proper operation, the unit must be powered by the voltage specified at the time of purchase.

Description

Line

Neutral

Color

Black

White

Outputs/PowerInputs Conduit

CCG+C21

21G

LNGNC NCNO NO

DS1

Conduit

Ground unit to protective earth post provided.

Chapter 1. Installation

Figure 6: CGA 351 Wiring Connections

CGA 351 User’s Manual 14

Chapter 3. Operation

3.1 Introduction

The CGA 351 is an easily-operated monitoring d evice. Before applying power , make sure the system has been installed in accordance with the instructions given in Chapter 2, Installation.

Note: For information regarding component locations and wiring connections in an optional enclosure, see

Appendix C.

Allow the unit to warm up for at least thirty minutes prior to use. Check to see if it is hot. Observe all normal safety precautions. Specifically, do not exceed the maximum pressure and temperature ratings of the zirconium oxide oxygen sensor and the sample system.

This chapter includes discussions of the following topics:

• preventing common problems

• powering up the system

• configuring the digital display

• taking measurements

WARNING!

To ensure safe operation of the CGA 351, it must be installed and operated as described in this manual. In addition, be sure to follow all applicable local safety codes and regulations for installing electrical equipment.

3.2 Preventing Common Problems

Use the CGA 351 to accurately measure low oxygen levels. To avoid problems, observe the following:

• Check the calibration of the analyzer once or twice a week for the first month of operation and once every

2–3 months thereafter (see Chapter 4, Setup and Calibration, for instructions).

• Never use thread sealant on any connection in the sample gas flow path. Thread sealant gives off combustible

vapors that can cause reading errors.

• Do not handle the oxygen sensor with bare hands. Although some scratches on the platinum coating can be

tolerated, rubbing the coating should be avoided.

• Clean the oxygen sensor only by rinsing it with clean water , after the sensor has cooled. Scrubbing the oxygen

sensor or washing a hot sensor in cold water can damage or destroy it.

• Do not disturb the special sealant on the oxygen sensor nut and the inlet fittings. Any leakage in these areas

will cause inaccurate readings when measuring low oxygen levels.

CGA 351 User’s Manual 15

Chapter 3. Operation

3.3 Powering Up the System

Before applying power, check the wiring connections and close both enclosures. Energize the external disconnect device to power up the CGA 351. For reliable readings, allow approximately two hours for the analyzer to reach temperature equilibrium before taking measurements.

WARNING!

IMPORTANT: For compliance with the European Union’s Low Voltage Directive (2006/95 /EC), th e CGA 351 requires

To prevent corrosion, the analyzer must be powered up immediately after introduction of the sample gas. If the analyzer is left installed without power, the unit’s components become susceptible to acid condensation that will cause corrosion.

If the power must be removed for more than thirty minutes, purge the analyzer through the inlet port with a continuous flow of instrument air at a rate of 400 ± 40 cc/min.

3.4 User Program Security

The CGA 351 has been equipped with a User Program (see the menu map in Figure 8 on page 25) that permits the setup and calibration of the instrument for optimum performance in any specific application. However, to prevent accidental changes to critical system parameters, four levels of security are imposed on the various submenus within the User Program. These are:

• Unlocked - access to these submenus is gained simply by pressing the [ESC] key. No password is required.

• Basic (locked) - access to these submenus is gained by pressing the [ESC], [ENT], and [ESC] keys in sequence.

Then, a password must be entered. (The default password is 2719.)

• General (locked) - access to these submenus is gained by pressing the [ESC], [ENT], and [ESC] keys in

sequence. Then, a password must be entered.

• Advanced (locked) - access to these submenus is gained by pressing the [ESC], [ENT], and [ESC] keys in

sequence. Then, a password must be entered.

Note: The passwords required for the three locked categories mentioned above are all different.

16 CGA 351 User’s Manual

Chapter 3. Operation

Display Window

ESC Button ENTER Button

Cursor Control Keypad

POWER Button

3.5 Configuring the Digital Display

The digital display panel at the top of the electronics enclosure includes the components shown in Figure 7 below.

A typical display will be configured to the customer’s needs at the factory. If changes are required, follow the instructions in this section to complete the initial configuration of the digital display. As an aid in performing this task, refer to the menu map in Figure 8 on page 25.

3.5.1 Initial Screen Displays

Immediately upon power up, the digital display shows the following sequence of informational screens, as the meter performs its internal systems checks:

Figure 7: Digital Display Panel

BSeries Loader v1.05 This is a typical example of

Boot is Flash. Program CRC valid. Booting from Flash

the first initialization screen.

Scanning Hardware This is a typical example of

Found Image Slot 1

the second initialization screen.

Downloading Slot 1

CGA 351 User’s Manual 17

Scanning Hardware This is a typical example of

Initializing Machine Initializing UI

the final initialization screen.

Chapter 3. Operation

3.5.1 Initial Screen Displays (cont.)

If the meter passes all of its internal system checks, the following screen appears:

1 Oxygen



This is a typical example of an initial screen.

Heater Warming

Note: The padlock icon at the upper right hand corner of the above display indicates that the User Program is locked

with password protection.

Before any data can be displayed, the meter must be configured for the desired display parameter(s). Enter the User Program by pressing the

IMPORTANT: In some applications, portions of the User Program may be locked to prevent end user access. If this is

[ESC] key and proceed as follows.

the case, entrance to these submenus requires a special key sequence and a password (see page 16).

3.5.2 Configuration Options

Cfg

Cal Opt Disp Upon entering the User

POWER ESC ENTER

Program, the already selected. Simply press

[ENTER]. (Notice that the [Disp] option is grayed out at

this time.

[Cfg] option is

Cfg

Cal Opt Disp To proceed with the [1: Cfg]

1: Cfg

option, press

[ENTER]. To

abort the operation, press

[ESC].

POWER ESC ENTER

From 1: Cfg A list of the available display

Oxygen

Temperature Sensor

inputs is shown. Use the [ and [

] keys to select the

desired input and press

[ENTER]. Oxygen has been

]

selected as an example.

POWER ESC ENTER

Note: The [CJC Temp] and [Duty Cycle] options are also available in the above list box.

18 CGA 351 User’s Manual

Chapter 3. Operation

3.5.2 Configuration Options (cont.)

From 1: Cfg Oxygen A list of the available unit

ppm

pcnt AF

POWER ESC ENTER

types is shown. Use the [ and [

] keys to select the

desired units (parts per million or percent) and press

If either of the Temperature inputs is selected for display, °C and °F are available as the unit types. For the Sensor and Duty Cycle inputs, mV and pcnt, respectively, are the only available unit types.

From 1: Cfg Ox..pcnt A list of the available output

*0: Display

*0: Fault Alarm

Add Remove

Cancel

devices is shown. Follow the instructions below to select the desired outputs.

]

[ENTER].

POWER ESC ENTER

Note: The

[0:Analog Output], [2:Alarm-1], [2:Alarm-2], [2:Alarm-3] and [2:Alarm-4] options are also available in the

above list box.

To select the desired output(s) from the previous list box, complete the following steps:

1. Use the [

] and [] keys to highlight a specific output. For this example, make sure that [0: Display] is selected as

one of the outputs.

2. Use the [

] and [] keys to select “Add” or “Remove” and press the [ENTER] key to change the status of the

selected output. An output is selected if an asterisk (*) appears to its left.

3. When all of the desired outputs have been selected, use the [

] and [] keys to select “OK” and press [ENTER].

1 Oxygen Press [ESC] four times to

2.71 ppm

return the display to the actual set configuration.

POWER ESC ENTER

Notice that the newly-configured display shows the slot number and the input parameter on the top line, and the current live value along with the unit type are displayed in the center of the screen.

Note: See Chapter 4, Setup and Calibration, for instructions on how to adjust the display contrast.

CGA 351 User’s Manual 19

Chapter 3. Operation

ARng

%O2()AR Zero()–

AR Span()AR Zero()–

----------------------------------------------------------

100× 75%==

3.5.3 Using the Auto Range Feature

The Auto Range feature includes three unit types:

• ARng (Auto Range %): the ratio of the current oxygen reading to the currently active Auto Range, expressed

as a percentage

• AR-A (Auto Range Alarm A): automatically set to a value of 0 or 1

• AR-B (Auto Range Alarm B): automatically set to a value of 0 or 1

As an example of how these units work with the default values listed in T a ble 3 on page 44, consider a situation where the current oxygen reading is 7.5%. The Auto Range feature would select the current active range as Range 3 in the table. Then,

(1)

This means that the current oxygen reading represents 75% of the currently active Auto Range. In addition to the ARng value calculated above, AR-A = 0 and AR-B = 1, as shown in the table.

After programming the Auto Ranges, the CGA 351 must be configured to properly h andle the Auto Range output. To accomplish this, the following outputs must be reprogrammed:

• Alarm A and Alarm B

• 4-20 mA analog output

3.5.4 Configuring the Alarms

The first step in setting up the alarms is to assign the correct unit types. T o accomplish this, proceed as follows from the Main Menu:

Cfg

Cal Opt Disp Upon entering the User

POWER ESC ENTER

Cfg

Cal Opt Disp To proceed with the [1: Cfg]

1: Cfg

Program, the already selected. Simply press

[ENTER].

option, press

[Cfg] option is

[ENTER].

POWER ESC ENTER

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