GE Sensing FGA311 Operating Manual

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Page 1

Sensing

FGA311

Panametrics In Situ Flue Gas Oxygen Analyzer

User’s Manual

910-160C1 March 2006

The FGA 311 In Situ Flue Gas Analyzer is a GE Panametrics product. GE Panametrics has joined other GE high-technology sensing businesses under a new name—GE Industrial, Sensing.

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March 2006

Warranty Each instrument manufactured by GE Infrastructure Sensing, Inc. is

warranted to be free from defects in material and workmanship. Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument, at the sole discretion of GE Infrastructure Sensing, Inc. Fuses and batteries are specifically excluded from any liability. This warranty is effective from the date of delivery to the original purchaser. If GE Infrastructure Sensing, Inc. determines that the equipment was defective, the warranty period is:

• one year for general electronic failures of the instrument

• one year for mechanical failures of the sensor

If GE Infrastructure Sensing, Inc. determines that the equipment was damaged by misuse, improper installation, the use of unauthorized replacement parts, or operating conditions outside the guidelines specified by GE Infrastructure Sensing, Inc., the repairs are not covered under this warranty.

The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory, express or implied (including warranties of merchantability and fitness for a particular purpose, and warranties arising from course of dealing or usage or trade).

Return Policy If a GE Infrastructure Sensing, Inc. instrument malfunctions within the

warranty period, the following procedure must be completed:

1. Notify GE Infrastructure Sensing, Inc., giving full details of the

problem, and provide the model number and serial number of the instrument. If the nature of the problem indicates the need for factory service, GE Infrastructure Sensing, Inc. will issue a RETURN AUTHORIZATION number (RA), and shipping instructions for the return of the instrument to a service center will be provided.

2. If GE Infrastructure Sensing, Inc. instructs you to send your

instrument to a service center, it must be shipped prepaid to the authorized repair station indicated in the shipping instructions.

3. Upon receipt, GE Infrastructure Sensing, Inc. will evaluate the

instrument to determine the cause of the malfunction.

Then, one of the following courses of action will then be taken:

• If the damage is covered under the terms of the warranty, the

instrument will be repaired at no cost to the owner and returned.

• If GE Infrastructure Sensing, Inc. determines that the damage is not

covered under the terms of the warranty, or if the warranty has expired, an estimate for the cost of the repairs at standard rates will be provided. Upon receipt of the owner’s approval to proceed, the instrument will be repaired and returned.

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Table of Contents

Chapter 1: General Information

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

The Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

The Heater Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chapter 2: Installation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Line Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Selecting the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Mounting the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Wiring the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Wiring the Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Wiring the Control Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Factory Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Reference Air and Calibration Gas Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Chapter 3: Operation and Programming

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Preventing Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Taking Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Data Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Programming Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Programming with Manual Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Description of Switches and LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Manual Programming Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Programming from a Computer Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

RS232 Serial Port Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

The OPTS Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Trim Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Extra Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Chapter 4: Calibration

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Recommended Calibration Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Measuring the Calibration Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

The Calibration Gas System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Calibrating the Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Calibrating with the Manual Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Calibrating with a PC Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

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Table of Contents (cont.)

Chapter 5: Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Sensor/Heater Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Temperature Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

ER2 Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

ER3 Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

ER4 Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Output Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

All Outputs Inactive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

No RS232 Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Oxygen Reading Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

ER1 Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Oxygen Percentage Always Reads 20.93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Oxygen Percentage Unchanged for more than 15 Minutes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Oxygen Reading Lower Than Expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Oxygen Reading Higher Than Expected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Chapter 6: Service and Maintenance

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Probe Tip Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Cover Removal and Reinstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Sensor/Heater Sub-Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Removing the Sensor/Heater Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Installing the Sensor/Heater Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Removing the Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Installing the Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

EPROM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Chapter 7: Specifications

Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Appendix A: The Nernst Equation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equilibrium Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

The FGA 311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

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Table of Contents (cont.)

Appendix B: FGA 311 Drawings

Appendix C: CE Mark Compliance

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

EMC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

LVD Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Appendix D: Data Records

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

User Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Test and Calibration Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Service Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

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Chapter 1

Page 7

General Information

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

The Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

The Heater Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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Introduction The FGA 311 In Situ Flue Gas Oxygen Transmitter monitors the

combustion efficiency of a boiler or furnace by measuring the percentage of oxygen in the flue gases. This self-contained instrument is installed so that its zirconium oxide oxygen sensor is located directly in the stream of the flue gases. The measurements may be recorded via the built-in 4-20 mA output or transmitted to a computer terminal via the built-in RS232 interface.

The FGA 311 is available with either the standard weatherproof enclosure or the optional explosion-proof enclosure, as shown in Figure 1-1 on page 1-2. However, the operation and the internal components are the same for both configurations.

The FGA 311 consists of the following sub-assemblies:

• An aluminum enclosure, which includes a breather port, the unit’s

mounting threads, a calibration gas connection and a reference air connection. In addition, the enclosure houses the printed circuit board and provides two ports for electrical conduit or cable glands.

• All of the electrical components, including the replaceable fuse,

are mounted on the printed circuit board (PCB). All electrical connections for the line power, 4-20 mA recorder output and RS232 interface are made to the PCB.

• A probe assembly that extends into the flue gas stream.

• A heater sub-assembly that maintains the oxygen sensor at the

proper operating temperature for efficient operation.

• A zirconium oxide oxygen sensor to measure the percentage of

oxygen in the flue gases.

• A filter assembly that protects the oxygen sensor from particulates

in the flue gas stream.

The FGA 311 has been designed to permit troubleshooting, maintenance and adjustment of the instrument without removing the unit from the flue.

General Information 1-1

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Standard

(Weatherproof)

Explosion-Proof

(Flameproof)

Side Views

Flame Arrestor

End Views

Flame Arrestors

Figure 1-1: The FGA 311 Enclosures

1-2 General Information

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Principles of Operation In an ideal combustion process, a precise ratio of air to fuel is burned

efficiently to yield only heat, water vapor, and carbon dioxide. However, because of burner aging, imperfect air to fuel mixtures, variable firing rates and/or inaccurate ignition timing, this situation rarely happens.

A sure sign of a less than ideal combustion process is the presence of excess oxygen in the flue gases. The level of this excess oxygen is easily monitored with the FGA 311 In Situ Flue Gas Oxygen Transmitter, and the information can then be used to make the necessary adjustments to improve the efficiency of the combustion process. The following two major components are included in the FGA 311 analyzer:

• a zirconium oxide oxygen sensor

• a loop-controlled heater circuit

These components are described in the sections that follow.

The Oxygen Sensor The inside and outside of the zirconium oxide oxygen sensor are

coated with a porous platinum catalyst, forming two electrodes. Flue gases flow past the outside of the sensor, while atmospheric air circulates freely on the inside of the sensor. The atmospheric air is used as the reference gas for the oxygen measurements. See the oxygen sensor sub-assembly shown in Figure 1-2 below.

At the normal operating temperature (650° to 1100°C) of the sensor, the oxygen molecules in the atmospheric reference air (20.93% oxygen) are electrochemically reduced at the inner electrode. The resulting oxygen ions seek an equilibrium with the lower oxygen concentration on the sample gas side of the sensor, by migrating through the porous ceramic toward the outer electrode.

Packing ScrewSleeveO-Ring

O-Ring Packing Oxygen Cell

Figure 1-2: The FGA 311 Oxygen Sensor

General Information 1-3

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The Oxygen Sensor (cont.)

At the outer electrode, the oxygen ions give up their extra electrons and revert to oxygen molecules, before being swept away by the flue gas stream. This exchange of electrons at the electrodes generates a voltage gradient across the sensor. See Figure 1-3 below.

The lower the concentration of oxygen in the flue gases, the greater the rate of ion migration through the ceramic and the higher the resulting voltage gradient across the sensor. In fact, the sensor’s voltage output rises logarithmically as the percentage of oxygen in the flue gases decreases. This enables the FGA 311 to accurately measure very small levels of oxygen in the flue gases.

Oxygen ions migrate through the Zirconium Oxide

from Inside to Outside

From Outside

Electrode

When O concentration in sample gas falls, cell voltage rises with increased O migration rate.

Volts

Zirconium Oxide Ceramic

with Lattice Imperfections

From Inside Electrode

Figure 1-3: Oxygen Migration Through the Sensor

1-4 General Information

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The Heater Control Circuit

The oxygen sensor temperature in the FGA 311 is maintained by a heater, which is part of a complex temperature control loop. This circuit constantly monitors the oxygen sensor temperature, compares it to the set point temperature (700°C), and turns the heater ON or OFF accordingly. The specific type of control circuit used is called a Proportional Integral Derivative (PID) loop, because of the three 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. Thus, decreasing this integration time reduces the offset more quickly.

• Derivative Action: The derivative portion of the control loop

applies a corrective signal based on the rate at which the actual temperature is approaching the set point. In effect, the derivative action reduces overshoot by counteracting the control signal produced by the proportional and integral parameters.

The heater control circuit is configured at the factory for optimum performance. Because of the strong interaction between the three parameters involved, properly setting up the PID loop is a very complex matter. As a result, randomly changing the P, I and/or O parameters can seriously degrade the performance of the FGA 311.

IMPORTANT: Always contact the factory before attempting to

change the default P, I and/or O values.

General Information 1-5

Page 13

Chapter 2

Page 14

Installation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Line Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Selecting the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Mounting the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Wiring the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Reference Air and Calibration Gas Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Page 15

March 2006

Introduction This chapter gives directions for the proper installation and wiring of

the FGA 311. The following specific topics are included:

• unpacking the unit

• selecting the site

• mounting the analyzer

• wiring the analyzer

!WARNING!

To ensure safe operation of the FGA 311, 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.

Unpacking the Unit Remove the analyzer from its shipping container and make sure that

all items on the packing slip have been received. If anything is missing, contact the factory immediately. The analyzer, as shown in Figure 2-1 below, is shipped fully assembled and ready to install.

3/4" NPT

Enclosure

4123

123

3/4" NPT

Caution!

When unpacking the analyzer, be careful not to damage

the probe. It is covered with a porous ceramic filter that

will easily crack if it is knocked against a hard surface.

PC Board

Calibration Gas Inlet

1-1/2" NPT

26-1/4"

Heater

19"

Probe

Sensor

Figure 2-1: The FGA 311 In Situ Flue Gas Analyzer

1-1/4"

Installation 2-1

Page 16

March 2006

Line Power Requirements Each FGA 311 analyzer is factory-configured for the proper line

voltage, as specified at the time of purchase. The available options include the following:

• Japan = 100 VAC

• U.S.A. = 110/120 VAC

• Europe = 220 VAC

• Australia = 240 VAC.

Caution!

To change the line voltage to the unit, contact the factory

for instructions. DO NOT make such a change without first

obtaining proper instructions.

Selecting the Site Environmental and installation factors should already have been

discussed with a GE Sensing applications engineer or field sales person before the FGA 311 arrives.The analyzer must be installed either in a furnace or boiler wall or in a flue duct. Ideally, the end of the probe assembly should extend approximately 1 ft (30.5 cm) into the flue gas stream. Also, the analyzer should be positioned so that the probe holes are on the downstream side of the probe (see Figure 2-2 on page 2-4).

• For furnaces, locate the analyzer close to the combustion zone,

typically within the radiant section and always before the convection section. Make sure that the probe’s maximum operating temperature is not exceeded and that the probe is not situated in a non-homogeneous flue gas mixture.

IMPORTANT: If the ambient temperature in the vicinity of the probe

can exceed 650°C (1202°F), a high temperature probe assembly is required.

• For boilers, locate the analyzer downstream of the heat exchanger

and just before the economizer air heater, if one is installed. The analyzer should not be placed downstream of any air heater, because of possible air leaks that can cause inaccurate readings.

In general, the sample point should be an area of high turbulence, which will ensure a good homogeneous mixture of the flue gases. Conditions to be avoided would include air leaks upstream of the sample point and dead spaces in the vicinity of the sample point.

2-2 Installation

Page 17

March 2006

Mounting the Analyzer The FGA 311 has integral male 1-1/2” NPT mounting threads. This

permits a flange to be threaded onto the analyzer, and the resulting assembly is then bolted to a mating flange on the furnace/boiler wall or flue duct.

Note: For installations where the FGA 311 may be exposed to water

or other fluids, install the unit with the breather (see Figure 2-2 on page 2-4) facing downward.

Do not use any thread sealant during the installation. Upon heating, Teflon tape will melt and other sealants may emit gases that interfere with the oxygen readings.

Carefully follow the instructions on page 2-5 to mount the FGA 311 In Situ Flue Gas Oxygen Transmitter. The unit may be mounted in either a horizontal or vertical orientation.

IMPORTANT: Direct mounting of the FGA 311 into a threaded hole

using its mounting threads is not recommended. Always use a mounting flange.

To prepare the installation site for mounting the analyzer, complete the following preliminary steps:

1. Fasten a short section of pipe having at least a 2” inside diameter

into the process wall.

IMPORTANT: Make sure that the pipe is long enough to permit

installation of the flange mounting hardware and that the flange is oriented with its bolt holes straddling the vertical and horizontal center lines.

2. Weld a mating flange onto the end of the pipe, as shown in

Figure 2-2 on page 2-4.

Note: Standard available factory options include 3”-300 lb ANSI,

4”-150 lb ANSI and DN80 PN16 mounting flanges. A separate mating flange can also be supplied with the unit.

Installation 2-3

Page 18

March 2006

GAS

FLOW

Input Scoop

GAS

Holes

FLOW

Standard Probe

Mounting Wall

Cable Gland

Calibration

1m, 1.5m & 2m Probes

90°

2" Min.

Hardware

Flanges

Gas Line

Gasket

FG311

Cable Gland

Control Cable

Power Cable

Reference

Air Line

Breather

Figure 2-2: Flange Mounting the FGA 311

2-4 Installation

Page 19

March 2006

Mounting the Analyzer (cont.)

Before mounting the FGA 311 analyzer assembly onto the mating flange, mark the enclosure in line with the probe holes. Then, complete the following steps:

IMPORTANT: The probe holes must be positioned on the

downstream side of the probe. See Figure 2-2 on page 2-4 for the proper orientation.

1. Slide the gasket over the probe assembly and up against the

mounting flange on the analyzer.

Note: Be sure to use a suitable high temperature gasket for this

application.

2. Orient the analyzer so the probe holes are properly positioned on

the downstream side of the probe, and slide the probe through the hole in the mounting wall until the two flanges meet.

3. Secure the analyzer in place by fitting bolts into the matching

flange mounting holes and fastening the bolts with nuts and washers. Make sure that the gasket is properly positioned between the two flanges.

This completes the mounting of the FGA 311. The required external connections are discussed in the following sections.

Installation 2-5

Page 20

March 2006

Wiring the Analyzer Connect the power and control signal wiring as described below and

as shown in Figure 2-3 on page 2-7, which shows the printed circuit board mounted within the open FGA 311 enclosure. The necessary connectors are supplied with the unit, and they are plugged into the mating connectors on the printed circuit board prior to shipment. DO NOT power up the unit until instructed to do so!

ATTENTION EUROPEAN CUSTOMERS!

In order to meet CE Mark requirements, all electrical cables

must be installed as described in Appendix C, CE Mark

Compliance.

Wiring the Line Power Use one of the 3/4” NPT connections on the enclosure for installation

of the power cable gland or conduit. The FGA 311 has been preset at the factory for the line voltage specified at the time of purchase. Never connect a different line voltage to the unit without first obtaining instructions from the factory.

!WARNING!

Improper connection of the power line or connection to the

wrong voltage may result in an electrical hazard.

Note: For compliance with the European Union’s Low Voltage

Directive (73/23/EEC), this unit 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 FGA 311.

The FGA 311 is designed to comply with the LVD Directive per the requirements of EN 61010 with the following exception: The 230 VAC unit passes with a test voltage of 1,800 VAC. (Refer to Table D.10 of Annex D in EN 61010.)

Connect the line power to terminal block TB1, as shown in Figure 2-3 on page 2-7, by completing the following steps:

1. Connect the

2. Connect the

LINE (black) lead to pin #1 on TB1.

NEUTRAL (white) lead to pin #2 on TB1.

3. Connect the

GROUND (green) lead to the earth ground screw inside

the enclosure.

Proceed to the next section to wire the control signals.

2-6 Installation

Page 21

March 2006

Heater Connections

J3 Terminal Block

1 2 3

Description

Heater No Connection Heater

NOTE: These connections are made

at the factory.

U15

TB2

MODE

CAL

ADJ

TB1 Power*

Terminal Block

Description

Line

Neutral

Power Voltage Options

Factory Installed

Power Jumpers Fuse

115V W1,W3,W4,W5 1/2A

W2,W6230V 1/4A

*Ground wire goes to

earth gnd connection.

0 1 E

4 3 R

FAULT

10E85

W6 W5

E11 E12

S D

3 S D

703-1216

TB1

C16

C15

U18

5 S D

RT1

C14

Fuse

RS232 Analog Output

TB2 Terminal Block

Pin Description

1Return 2 Receive 3Send 4 4-20 mA Out– 5 4-20 mA Out+

RS232

Thermocouple and Sensor

J2 Terminal Block

Thermocouple +

Thermocouple –

Zirconium Oxide Oxygen Sensor + Zirconium Oxide Oxygen Sensor –

Description

Future Use (CJC+)5

NOTES:

1. PC Board may be oriented differently, depending on how the unit is installed.

Future Use (CJC–)6

NOTE: These connections are made

at the factory.

2. J1 is reserved for future use.

(Shown with sensor/heater assembly and cable removed for clarity.)

Figure 2-3: Connections to the FGA 311 PC Board

Installation 2-7

Page 22

March 2006

Wiring the Control Signals Use the remaining 3/4” NPT port on the FGA 311 enclosure for

connecting the control cable gland or conduit. For cable runs of less than 5 m (16.4 ft), standard twisted pair cable may used for these connections. However, shielded cable should be used for longer cable lengths and/or for CE Mark compliance.

IMPORTANT: This symbol indicates Caution - risk of electric

shock:

The control signal connections are made to the printed circuit board on terminal block TB2, as shown in Figure 2-3 on page 2-7. To make the necessary connections, complete the following steps:

1. Connect the RS232 serial port leads to TB2 as follows:

Note: The serial port connection should be made with a GE Sensing

#704-668 cable assembly or its equivalent. To assemble an equivalent cable, refer to Figure B-6 in Appendix B of this manual.

a. Connect the

Ground lead (the green wire from pin #5 of the

DB9 connector on the PC) to pin #1.

b. Connect the

Receive lead (the red wire from pin #2 of the DB9

connector on the PC) to pin #2.

c. Connect the

Transmit lead (the white wire from pin #3 of the

DB9 connector on the PC) to pin #3.

2. Connect the 4-20 mA analog output leads to TB2 as follows:

a. Connect the 4-20 mA b. Connect the 4-20 mA

Return (-) lead to pin #4.

Signal (+) lead to pin #5.

Proceed to the next section for a description of the internal, factoryinstalled wiring.

2-8 Installation

Page 23

March 2006

Factory Connections In addition to the user connections described above, the following

connections are made at the factory to terminal blocks J2 and J3.

• Thermocouple connections to J2 on pins #1 (+) and #2 (-).

• Oxygen sensor connections to J2 on pins #3 (+) and #4 (-).

• Heater connections to J3 on pins #1 and #3.

For reference purposes only, these factory connections are shown in Figure 2-3 on page 2-7.

Reference Air and Calibration Gas Lines

During normal operation, the FGA 311 requires a constant supply of a reference air for the zirconium oxide oxygen sensor. The recommended gas for this purpose is instrument air (containing

20.93% oxygen) at a flow rate of 20-50 cc/min. Connect this gas supply, with 1/4” tubing, to the 1/4” compression fitting provided. Refer to Figure 2-4 on page 2-10 for the location of this connector.

Also, a separate gas supply is required for calibration of the instrument. This line should be connected, with 1/4” tubing, to the remaining 1/4” compression fitting on the FGA 311. See Figure 2-4 on page 2-10 for the location of this connector.

Note: The calibration gas port must remain capped, if no permanent

plumbing is attached. See Chapter 4, Calibration, for a discussion of the recommended calibration gases and procedures.

In addition to the basic reference air and calibration gas lines, a variety of ancillary equipment is recommended. A typical system that will ensure efficient and reliable operation of the FGA 311 is illustrated in Figure 2-4 on page 2-10.

Installation 2-9

Page 24

March 2006

Valve

Flowmeter

Calibration Gas Inlet

Gauge

Tee

Valve

Calibration Gas Supply

Reference Air Inlet

Flowmeter

Gauge

Valve

Tee

Reference Air Supply

Figure 2-4: A Typical FGA 311 System

2-10 Installation

Page 25

Chapter 3

Page 26

Operation and Programming

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Preventing Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Taking Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Data Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Programming Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Programming with Manual Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Programming from a Computer Terminal . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Page 27

March 2006

Introduction Since the FGA 311 In Situ Flue Gas Oxygen Transmitter is a

monitoring device, operation of the installed analyzer is simple. Once it has been properly installed and set up, it will simply begin taking readings. However, the analyzer should be allowed to warm up for at least one hour (three hours if possible) prior to use. See Chapter 2, Installation, if all of the required installation requirements have not yet been completed.

Calibration of the unit should be checked once or twice a week for the first month of operation and once every 2-3 months thereafter. See Chapter 4, Calibration, for the correct procedures.

!WARNING!

To ensure safe operation of the FGA 311, 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

Preventing Common Problems

Because of the extreme conditions in monitoring flue gases and the complexity of the FGA 311’s measurement techniques, some simple precautions should be taken with the instrument. Failure to observe these basic procedures can lead to operational difficulties. Compliance with the following instructions will help to eliminate such common problems:

• Do not use pipe thread compounds on any part of the FGA 311.

Many pipe thread compounds emit combustible vapors that may cause inaccurate readings.

• Do not handle the sensor assembly any more than is absolutely

necessary. Although some scratches on the platinum electrode can be tolerated, rubbing the coating should be avoided. Also, the transfer of skin oils to the electrode can cause erroneous readings.

• Scrubbing the sensor while washing it or washing a hot sensor can

damage or destroy it. Clean the sensor only by rinsing it with clean water, after the sensor has cooled.

• Installing a cold probe assembly into a hot flue gas stream can

cause damage to the filter and/or sensor. Always allow the probe assembly to gradually heat up to normal operating temperature, before subjecting it to hot flue gases.

If any problems not covered in this manual are encountered, contact a GE Sensing representative for assistance.

Operation and Programming 3-1

Page 28

March 2006

Powering Up Before powering up the unit, start the flow of reference air. Be sure

that the reference air source is connected to the correct port, as shown in Figure 2-4 on page 2-9. As stated in Chapter 2, Installation, the recommended reference air is instrument air (20.93% oxygen) at a flow rate of 20-50 cc/min.

Note: The zirconium oxide oxygen sensor can not provide accurate

readings without a known oxygen percentage on the reference side of the cell. Allow the reference air to flow for at least five minutes prior to operation.

Power may now be applied to the unit. Since the FGA 311 does not have its own power switch, the main disconnect must be used to power the analyzer on. Simply place this switch in the ON position, and allow the analyzer to warm up for at least one hour (three hours if possible) before taking any readings.

Note: For compliance with the European Union’s Low Voltage

The red fault light (DS4) and one of the green oxygen range indicators (DS1, DS2 or DS3) on the printed circuit board will blink until the FGA 311 has reached its normal operating temperature of 700°C. Then, the fault light will go out and the range indicator will glow steadily.

3-2 Operation and Programming

Page 29

March 2006

Taking Measurements After the FGA 311 has warmed up, the voltage output of the

zirconium oxide oxygen sensor will vary logarithmically with the oxygen concentration in the flue gases, according to the Nernst equation (see Appendix A, The Nernst Equation, for details):

20.93

EmV()48.274

In Equation 3-1 above, “E” is the voltage in millivolts generated by the sensor at an operating temperature of 700°C.

The built-in thermocouple temperature sensor in the FGA 311 automatically adjusts the constant used in the Nernst equation to reflect the precise actual temperature of the oxygen sensor. In addition, the non-linear output voltage signal generated by the oxygen sensor is internally converted into a linear 4-20 mA output current signal, which is sent to pins 4 and 5 of terminal block TB2. The 4-20 mA current range corresponds to a flue gas oxygen range of 0% to the programmed O

ammeter or a recording device to these terminals, the oxygen content of the flue gases may be continuously monitored.

range (5, 10 or 25%). By connecting a digital

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

log•=

(3-1)

Data Records Appendix D, Data Records, at the back of this manual provides

several tables for entering all of the relevant data pertaining to the installation and programming of the FGA 311. Be sure to maintain the accuracy of this data on a regular basis. In the event of problems with the unit, the data records may provide valuable information to assist in the troubleshooting procedure.

Menu Map A complete menu map of the FGA 311’s built-in software is shown in

Figure 3-3 on page 3-22. Refer to this figure as needed to supplement the step-by-step programming instructions that follow.

Programming Options The following two methods for programming the FGA 311 In Situ

Flue Gas Oxygen Transmitter may be used to navigate through the User Program:

• manual switches, which are located inside the enclosure, on the

analyzer’s printed circuit board

• a terminal or computer, utilizing the unit’s built-in RS232 serial

interface

Note: The entire

programming switches.

EXTRA menu is not accessible via the manual

Operation and Programming 3-3

Page 30

March 2006

Programming with Manual Switches

CAL S3

MODE

Manual programming of the FGA 311 is accomplished with a series of switches and LEDs located on the printed circuit board. These components, which are shown in Figure 3-1 below, may be accessed by removing the cover from the FGA 311.

Although the menu map shown in Figure 3-3 on page 3-22 does apply to both the manual programming mode and the RS232 programming mode, some of the programming options are not available via the manual switches. Specifically, the entire EXTRA menu can not accessed via the PC board switches.

TB1

C14

C16

C15

U18

RT1

DS5

TB2

5 10

FAULT

4 S D

U15

CAL

TB2

MODE

ADJ

0 1 E

4 3 R

FAULT

10E85

W6 W5

E11 E12

S D

703-1216

5 S D

ADJ

Figure 3-1: Circuit Board Switches and LEDs

3-4 Operation and Programming

Page 31

March 2006

Description of Switches and LEDs

The following switches and lights will be found on the printed circuit board of the FGA 311:

• MODE Switch S1: a 10-position rotary switch that is used to select

the desired menu option.

• ADJ Switch S2: a rotary encoder switch used to adjust the value of

numeric menu options selected with Switch S1.

• CAL Switch S3: a push-button switch used to enter and exit

programming mode and to confirm the programming option set with Switch S1.

• DS1-DS3: three green LEDs that are used to indicate the selected

oxygen range setting.

• DS4: a red LED that is used as a fault indicator.

• DS5: a yellow LED that indicates the heater duty cycle.

The specific menu options that may be selected with the 10-position rotary

MODE Switch S1 are listed in Table 3-1 below.

Table 3-1: MODE Switch S1 Positions

Switch Position Menu Option

0TST 1AIR 2GAS 3RNG 4TRIM_O2 4mA 5 TRIM_O2 20mA 6Not Used 7Not Used 8Not Used 9Not Used

Note: Only six of the ten positions on Switch S1 (0-5) are currently

active. Positions 6–9 are not used at this time.

Navigating through the FGA 311’s built-in User Program software is easily accomplished by completing the detailed steps in the following section.

Operation and Programming 3-5

Page 32

March 2006

Manual Programming Instructions

Use the following instructions to program the FGA 311 with the printed circuit board switches:

Set Switch S1 = 0 Push

CAL Switch S3 and hold for 5

seconds to access the TST option. The red Fault LED (

DS4) will light

if the sensor is bad, or the three green LEDs (

DS1-DS3) will light if

the sensor is good. Press Switch S3 and hold for 5 seconds to

EXIT

programming mode.

Set Switch S1 = 1 Push

CAL Switch S3 and hold for 5

seconds to set the AIR calibration. A green LED will blink until the calibration is complete. Press Switch S3 and hold for 5 seconds to

EXIT programming mode.

IMPORTANT: Always complete the

attempting the LED may glow temporarily during the

AIR calibration before

GAS calibration. Also, The red fault

GAS

calibration procedure.

Set Switch S1 = 2 Push

CAL Switch S3 and hold for 5

seconds to set the Adjust the value with

GAS calibration.

ADJ Switch

S2 until a green LED starts blinking. Press Switch S3 and hold for 5 seconds to EXIT programming mode.

Note: Refer to Chapter 4, Calibration, for a detailed description of

the calibration procedures.

Set Switch S1 = 3 Push

CAL Switch S3 and hold for 5

seconds to access the RANGE option. The current O

range LED

will blink. Adjust the value with

ADJ Switch S2 until the green

LEDs start blinking. Press Switch S3 and hold for 5 seconds to EXIT programming mode.

3-6 Operation and Programming

Page 33

Manual Programming Instructions (cont.)

March 2006

Set Switch S1 = 4 Push

CAL Switch S3 and hold for 5

seconds to access the TRIM_O2 4mA option. Adjust the value with

ADJ Switch S2 until the output

signal reads 4 mA. Press Switch S3 and hold for 5 seconds to EXIT programming mode.

Note: For the TRIM_O2 function, always adjust the 4 mA setting

before

the 20 mA setting. This will ensure optimum accuracy

of the instrument.

Set Switch S1 = 5 Push

CAL Switch S3 and hold for 5

seconds to access the TRIM_O2 20mA option. Adjust the value with

ADJ Switch S2 until the

output signal reads 20 mA. Press Switch S3 and hold for 5 seconds to EXIT programming mode.

After the programming has been completed, reinstall the cover on the FGA 311 enclosure. Do not operate the FGA 311 permanently with the cover removed.

Operation and Programming 3-7

Page 34

March 2006

Programming from a Computer Terminal

In the following instructions, the actual terminal screen display is shown in the left column, while the required user response is shown in the right column. Keyboard inputs are indicated by square brackets (i.e. [ESC] means to press the “escape key” on the keyboard). Also, to change a displayed numeric value, use the

[+] and [-] keys to adjust the

current value to the desired setting.

For reference, the screen display of a typical menu line is shown in Figure 3-2 below. This figure pictures the menu line that appears on the terminal screen, as soon as the User Program has been accessed. Note the location of the selection brackets, which highlights the current menu choice.

Menu Choices

TRIM EXTRA[OPTS]

Selection Brackets

Figure 3-2: A Typical Menu Line

Navigating through the User Program is easy, using the keystrokes in Table 3-2 below and the instructions in the following sections.

Table 3-2: Computer Terminal Keyboard Entries

Desired Action Keyboard Entry

Move from run mode to programming mode [ESC] Move from programming mode to run mode Move selection brackets Enter numerical data

Confirm selection or entry Start entry over again Move up one level in program

[ESC]

[SPACE]

, [-]

[+]

[ENTER] [BACKSPACE] [BACKSPACE]

Note: The use of any keys on the keyboard other than those listed in

Table 3-2 above will not be recognized by the FGA 311. Any such keyboard entries will simply be ignored by the analyzer.

[+] is a shifted key, and the [SHIFT] key must be held while

Also, striking it.

3-8 Operation and Programming

Page 35

March 2006

RS232 Serial Port Settings Before the FGA 311 may be programmed via its built-in RS232

interface, the serial port of the personal computer (PC) must be configured to the following specifications:

• 9600 Baud

• 8 Data Bits

• 1 Stop Bit

• No Parity

• Xon/Xoff Flow Control

Note: If the RS232 connection still does not work, try reversing the

leads on pins 2 and 3 of terminal block

Refer to the computer’s documentation for the correct procedures to configure and access the serial port. Then, proceed to the next section to begin programming the analyzer.

The OPTS Menu Use the following procedure to move through the OPTS menu.

TB2.

RUN 20.93% O2 700.0C Press

Note: While in the

time by pressing the

[OPTS] TRIM EXTRA Make sure

OPTS menu, you may return to run mode at any

[ESC] key.

[ESC] to move from run mode

to the main menu.

OPTS is highlighted and

then press

[ENTER].

Oxygen Sensor Test IMPORTANT: The oxygen sensor test must be done while the

instrument is measuring

[TST] AIR GAS RNG Make sure TST is highlighted and

then press

TEST PASSED xxx.x% One of these two screens will

appear. Press

TEST FAILED xxx.x%

to the

GAS (not AIR).

[ENTER].

[BACKSPACE] to return

OPTS menu.

Press

[ESC] to return to run mode, or proceed to the next section to

continue programming the

Operation and Programming 3-9

OPTS menu.

Page 36

March 2006

Air Measurement Calibration

TST [AIR] GAS RNG Press [SPACE] to select AIR and

then press

[ENTER].

Gas Measurement Calibration

AIR 20.93%O2 xxx.xC Press

[ENTER] to accept the new

offset value and return to the just press

OPTS menu.

the

[BACKSPACE] to

OPTS menu. To abort,

[BACKSPACE] to return to

Note: Refer to Chapter 4, Calibration, for a detailed description of

the calibration procedures.

[ESC] to return to run mode, or proceed to the next section to

Press continue programming the

OPTS menu.

TST AIR [GAS] RNG Press [SPACE] to select GAS and

then press

GAS [x.xx]%O2 xxx.xC Adjust the

and

[ENTER].

O2 value with the [+]

[-] keys. Press [ENTER] to

accept the new value and

[BACKSPACE] to return to the OPTS

menu. To abort, just press

[BACKSPACE] to return to the OPTS

menu.

Press [ESC] to return to run mode, or proceed to the next section to continue programming the

OPTS menu.

Set Oxygen Range

TST AIR GAS [RNG] Press [SPACE] to select RNG and

then press

[O2_RNG] TEMP_RNG Make sure

then press

5% [10%] 25% Press

oxygen range and press Press

RNG menu.

3-10 Operation and Programming

[ENTER].

O2_RNG is selected and

[ENTER].

[SPACE] to select the desired

[ENTER].

[BACKSPACE] to return to the

Page 37

March 2006

Trim Menu Use the following procedure to move through the TRIM menu.

Trim Oxygen Output

RUN 20.93%O2 700.0C Press

[ESC] to move from run mode

to the User Program.

Note: While in the

time by pressing the

OPTS [TRIM] EXTRA Press

TRIM menu, you may return to run mode at any

[ESC] key.

[SPACE] to select TRIM and

then press

[ENTER].

[TRIM_O2] TRIM_TEMP Make sure TRIM_O2 is highlighted

and press

[ENTER].

Note: For the TRIM_O2 function, always adjust the 4 mA setting

before the

20 mA setting. This will ensure that the instrument

operates at optimum accuracy.

TRIM_O2 mA: [4] 20 Make sure “

then press

4” is highlighted and

[ENTER].

4mA_O2 [xxx] ADJUST Using

[+] and [-], adjust the value

to obtain an output signal of 4 mA.

[ENTER] to accept the new

Press value. Press

[BACKSPACE] to back

up one menu level.

TRIM_O2 mA: 4 [20] Press

20mA_O2 [xxx] ADJUST Using

[SPACE] to select “20” and

then press

[ENTER].

[+] and [-], adjust the value

to obtain an output signal of 20 mA. Press new value. Press

[ENTER] to accept the

[BACKSPACE]

twice to return to the

Press

[ESC] to return to run mode, or proceed to the next section to

continue programming the

TRIM menu.

Operation and Programming 3-11

Page 38

March 2006

Extra Menu Use the following procedure to move through the EXTRA menu.

RUN 20.93%O2 700.0C Press [ESC] to move from run mode

to the User Program.

Selecting Terminal Type

Note: While in the

time by pressing the

OPTS TRIM [EXTRA] Press

[COM] ERR PID FRZ RESP OFST

[TTY] ANSI Press

EXTRA menu, you may return to run mode at any

[ESC] key.

[SPACE] to select EXTRA and

then press

[ENTER].

Make sure COM is selected and then press

[SPACE] to select the desired

option and then press return to the

[BACKSPACE].

[ENTER].

[ENTER]. To

EXTRA menu, press

Note: Select TTY to interface the FGA 311 with a Teletype terminal,

or select ANSI to use a computer terminal that communicates via the standard ASCII character set. For most modern personal computers, select the ANSI option.

[ESC] to return to run mode, or proceed to the next section to

Press continue programming the

EXTRA menu.

3-12 Operation and Programming

Page 39

Error Handling Set Up

March 2006

COM [ERR] PID FRZ RESP OFST

Press [SPACE] to select ERR and then press

[ENTER].

This sub-menu permits set up of the responses of the FGA 311 to various error situations. The following error states may be configured via this menu:

• ER1: the Sensor Failure! error message.

• ER2: the Warning: Warming Up! error message.

• ER3: the Open Thermocouple! error message.

• ER4: the Heater Failure! error message.

When all of the desired error handling options have been set, press

[ESC] to return to run mode, or proceed to the next section to continue

programming the

Proceed to the desired section(s) now to set any or all of the available error handling functions.

EXTRA menu.

ER1: the

Sensor Failure! error message

[ER1] ER2 ER3 ER4 Make sure ER1 is highlighted and

then press

[ENTER].

Proceed to either the “Disable ER1” or “Set ER1” prompt.

[ER1-OFF] ER1-SET To disable [Disable ER1]

is highlighted and then press

[ENTER]. Press [BACKSPACE] to back

ER1, make sure ER1-OFF

up one menu level.

ER1-OFF [ER1-SET] To set [SET ER1]

ER1, press [SPACE] to select

ER1_SET and press [ENTER].

ER1 [xx.x] mA Enter the desired value and press

[ENTER]. Press [BACKSPACE] to back

up one menu level.

Operation and Programming 3-13

Page 40

March 2006

Error Handling Set Up (cont.)

ER2: the Warning: Warming Up! error message.

ER1 [ER2] ER3 ER4 Press

[SPACE] to select ER2 and

then press

[ENTER].

Proceed to either the “Disable ER2” or “Set ER2” prompt.

[ER2-OFF] ER2-SET To disable [Disable ER2]

is highlighted and then press

[ENTER]. Press [BACKSPACE] to back

ER2, make sure ER2-OFF

up one menu level.

ER2-OFF [ER2-SET] To set [SET ER2]

ER2, press [SPACE] to select

ER2_SET and press [ENTER].

ER2 [xx.x] mA Enter the desired value and press

[ENTER]. Press [BACKSPACE] to back

up one menu level.

ER3: the

ER1 ER2 [ER3] ER4 Press

Open Thermocouple! error message.

[SPACE] to select ER3 and

then press

[ENTER].

Proceed to either the “Disable ER3” or “Set ER3” prompt.

[ER3-OFF] ER3-SET To disable [Disable ER3]

is highlighted and then press

[ENTER]. Press [BACKSPACE] to back

ER3, make sure ER3-OFF

up one menu level.

ER3-OFF [ER3-SET] To set [SET ER3]

ER3, press [SPACE] to select

ER3_SET and press [ENTER].

ER3 [xx.x] mA Enter the desired value and press

[ENTER]. Press [BACKSPACE] to back

up one menu level.

3-14 Operation and Programming

Page 41

March 2006

Error Handling Set Up (cont.)

ER4: the Heater Failure! error message.

ER1 ER2 ER3 [ER4] Press

[SPACE] to select ER4 and

then press

[ENTER].

Proceed to either the “Disable ER4” or “Set ER4” prompt.

[ER4-OFF] ER4-SET To disable [Disable ER4]

is highlighted and then press

[ENTER]. Press [BACKSPACE] to back

ER4, make sure ER4-OFF

up one menu level.

ER4-OFF [ER4-SET] To set [SET ER4]

ER4, press [SPACE] to select

ER4_SET and press [ENTER].

ER4 [xx.x] mA Enter the desired value and press

[ENTER]. Press [BACKSPACE] to back

up one menu level.

Operation and Programming 3-15

Page 42

March 2006

Set Up Heater Control Although the default values for the P and I parameters of the

FGA 311 PID heater control circuit are suitable for most applications, it may sometimes be necessary to fine-tune these parameters. Refer to Chapter 1, General Information, for a discussion of the PID circuit. If an adjustment is indicated, proceed as follows:

IMPORTANT: Always consult the factory before changing the P

and/or I values.

COM ERR [PID] FRZ RESP OFST

Press [SPACE] to select PID and then press

[ENTER].

Proceed to the appropriate section to set the desired parameter.

SET: specify the temperature set point (normally 700°C).

[SET] P I O DEFAULT Make sure

then press

SET is highlighted and

[ENTER].

SET [xxx] Degrees C Enter the desired set point value

and press

Press

[ESC] to return to run mode, or proceed to the next section to

continue programming the

PID sub-menu.

[ENTER].

P: set the proportional band value.

SET [P] I O DEFAULT Press

[SPACE] to select “P” and then

press

[ENTER].

P [xxx] Degrees C Enter the desired proportional

band value and press

[ESC] to return to run mode, or proceed to the next section to

Press continue programming the

3-16 Operation and Programming

PID sub-menu.

[ENTER].

Page 43

March 2006

Set Up Heater Control (cont.)

I: set the integration time value.

SET P [I] O DEFAULT Press

[SPACE] to select “I” and then

[ENTER].

press

I [xxx] Seconds Enter the desired integration time

value and press

Press

[ESC] to return to run mode, or proceed to the next section to

continue programming the

PID sub-menu.

[ENTER].

O: set the overheat value.

SET P I [O] DEFAULT Press

[SPACE] to select “O” and then [ENTER].

press

P [xxx] Degrees C Enter the desired overheat value

and press

[ENTER].

Note: The overheat value should be set to the highest process

temperature (acceptable values are 600 – 1200°C). The default value is 820°C.

Press

[ESC] to return to run mode, or proceed to the next section to

continue programming the

DEFAULT: restore the factory default

PID sub-menu.

SET, P, I and O values.

SET P I O [DEFAULT] To restore the default values, press

[SPACE] to select DEFAULT and press [ENTER].

[ESC] to return to run mode, or proceed to the next section to

Press continue programming the

EXTRA menu.

Operation and Programming 3-17

Page 44

March 2006

Freeze a Reading In some situations, it may be helpful to freeze an output reading for

viewing at a more convenient time. To accomplish this, perform the following steps:

COM ERR PID [FRZ] RESP OFST

[FREEZE] UNFREEZE Press

Press [SPACE] to select “FRZ” and then press

[SPACE] to select the desired

menu choice and press Press

[BACKSPACE] to back up one

[ENTER].

menu level.

[ESC] to return to run mode. If FREEZE was selected above, the

Press output display will constantly show the last good reading, until the

UNFREEZE option is selected in this sub-menu.

Setting the Response Time The response time of the FGA 311 may be adjusted using this sub-

menu. A shorter response time will provide by more accurate data by updating the display more frequently, but a longer response time will provide a more stable display that is free from flicker.

COM ERR PID FRZ [RESP] OFST

Press [SPACE] to select RESP and then press

[ENTER].

RESP [xx] Seconds Enter the desired response time

(values from 1 to 30 seconds are acceptable) and press

[ESC] to return to run mode, or return to a previous section to

Press continue programming the

PID sub-menu.

[ENTER].

3-18 Operation and Programming

Page 45

March 2006

Setting the Duty Cycle/ Offset

The offset value is subtracted from the “Raw O2 mV” value with the difference showing in the “O2 mV” value. The amount of duty cycle/ offset table entries can range from 0 to 5 and they do not have to be entered in any type of order. The calculation of the offset value to subtract depends on the following cases:

1. One duty cycle/offset entry only: The offset entry in this case

will be used universally, that is, the same offset will be used no matter what the duty cycle.

2. More that one activated entry and measured duty cycle falls

between two entered duty cycle values from the table: The

software will choose the closest duty cycle values above and below the measured duty cycle. The offset value will be interpolated based on the chosen entries.

3. Measured duty cycle value falls above or below any table

value: The offset value will clamp to the lowest or highest table

entry in terms of duty cycle.

4. No entry activated or whole table de-activated: The offset value

will be zero.

COM ERR PID FRZ RESP [OFST]

Press [SPACE] to select "OFST” and then press

[ENTER].

Use Offset Table YES [NO] Observe the Offset enable Yes/

No menu and press the “D” key.

Run time data should appear or disappear depending on the prior setting. Selecting “NO” from the offset enable choices will give a message of “DUTY CYCLE OFFSET TABLE ENABLED.” No table should appear below (that is, if “D” had been pressed to clear any previous display of the table).

Use Offset Table [YES] NO Press

[SPACE] to select “YES”

and then press

[ENTER].

The offset table should appear at the bottom of the screen. The offset table gives the user entered Duty Cycle values with their corresponding offset values. Also the line above the table headers should read that the offset is enabled in addition to displaying the current % duty cycle reading and the calculated offset value.

Operation and Programming 3-19

Page 46

March 2006

Setting the Duty Cycle/ Offset (cont.)

DC/Ofst Entries [1] 2 3 4 5 Select number “1” from the DC/

Offset Entries menu and press

[ENTER].

Use Entry 1 [YES] NO Select “Yes” for Use Entry 1 and

press

[ENTER].

Choosing “Yes” activates a DC/Offset entry and will be used for offset calculations. The table entry for entry 1 should now show “Enabled.” The offset reading above the table should now display a value other than zero.

Entry 1 [DC] Offset To change the DC value, select

“DC” and press

[ENTER].

Entry 1 DC [Offset] To change the Offset value,

select “Offset” and press

[ENTER].

All entries (1-5) are edited in the same way. Press

[ESC] to return to

run mode.

3-20 Operation and Programming

Page 47

TST

TST PASSED xxx.x%

TST FAILED xxx.x%

COM

TTY

ANSI

ER1

ER1_OFF

ER1_SET

March 2006

ER1 xx.x mA

OPTS

TRIM

AIR

GAS

RNG

TRIM_O2

AIR 20.93% O2 xxx.xC

GAS x.xx%O2 xxx.xC

O2_RNG

TRIM_O2 mA: 4 20

5 10 25

4mA_O2 xxx ADJUST

20mA_O2 xxx ADJUST

ERR

PID

ER2

ER3

ER4

SET

ER2_OFF

ER2_SET

ER3_OFF

ER3_SET

ER4_OFF

ER4_SET

SET xxx Degrees C

P xxx Degrees C

I xxx Seconds

ER2 xx.x mA

ER3 xx.x mA

ER4 xx.x mA

Figure 3-3: FGA 311 Menu Map

O O xxx Degrees C

EXTRA*

* not accessible

using

manual switches

FRZ

RESP

OFST [1] 2 3 4 5

The user will respond "Yes" or "No" to some options.

DEFAULT

FREEZE

UNFREEZE

RESP xx Seconds

DUTY CYCLE

OFFSET

Operation and Programming 3-21

Page 48

Chapter 4

Page 49

Calibration

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Recommended Calibration Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Measuring the Calibration Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

The Calibration Gas System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Calibrating the Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Page 50

March 2006

Introduction As stated in Chapter 3, Operation and Programming, the calibration

of the FGA 311 In Situ Flue Gas Oxygen Transmitter should be checked once or twice a week during the first month of operation and every 2-3 months thereafter. Changes in calibration may result from aging of the oxygen sensor, and within limits, temperature calibration adjustments can compensate for such variations.

!WARNING!

To ensure safe operation of the FGA 311, 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.

IMPORTANT: This symbol indicates Caution - risk of electric

shock:

Recommended Calibration Gas

Calibration of the FGA 311 analyzer requires a calibration gas of precisely known composition. The following calibration gas is recommended by GE Sensing:

• 5.0% O

+ 95.0% N

Note: The calibration gas cylinder must be certified as to the exact

composition of the gas.

A 5.0% O

calibration gas should produce an oxygen sensor voltage

output of 30.0 ± 1.5 mV, at the usual sensor operating temperature of 700°C. The corresponding 4-20 mA analog output will depend on the programmed oxygen range, as shown in Table 4-1 below.

Table 4-1: Calibration Gas Current Outputs

Range 0% O

5% O

Max.% O

5% 4.0 mA 20.0 mA 20.0 mA 10% 4.0 mA 12.0 mA 20.0 mA 25% 4.0 mA 7.2 mA 20.0 mA

Other calibration gases may be used, as long as the oxygen content of the calibration gas is approximately equal to the oxygen percentage in the flue gases to be measured. Of course the voltage output of the oxygen sensor and the corresponding 4-20 mA analog output will differ from those noted above. Also, these values will vary if the oxygen sensor temperature is different from the standard 700°C.

Calibration 4-1

Page 51

March 2006

Measuring the Calibration Response

Refer to Appendix A, The Nernst Equation, to calculate the expected oxygen sensor output voltage at whatever O

% and operating

temperature are being used. Calculate the corresponding 4-20 mA analog output signal using Equation 4-1 below.

oxygen percentage

current (mA) 4=16

For example, if the calibration gas is 2% O

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

•+ range setting

and the O2 range is set to

(4-1)

5%, the mA output should be 4 + 16 (2/5) = 10.4 mA. Figure 4-1 on page 4-3 shows a graphical representation of the procedure. For the same example, pick the applicable range curve (R = 5). Then, move from the chosen oxygen percentage (2.0) on the horizontal axis up to the range curve, and move across to the vertical axis to read the correct analog output (10.4 mA).

To monitor the analyzer’s response to the calibration gas, remove the lead from pin 4 (–) or pin 5 (+) on terminal block TB2 and install a digital ammeter between the removed lead and the pin. The current should measure within ±0.3 mA of the 5% O

readings listed in Table

4-1 on page 4-1. Alternatively, the oxygen sensor voltage output may be measured directly by connecting a digital voltmeter across pins 3 (+) and 4 (–) of terminal block J2.

The Calibration Gas System

The calibration gas should be introduced to the FGA 311 by a system similar to the one shown in Figure 2-4 on page 2-10. The calibration port plug that is supplied with the FGA 311 must be removed and a temporary connection made, to calibrate the oxygen sensor. However, if a permanent connection is preferred, it should be as short as possible and it should include an isolation valve next to the calibration gas port on the analyzer.

IMPORTANT: The reference air supply to the FGA 311 must be

maintained at its normal flow rate throughout the calibration procedure.

To accurately calibrate the FGA 311, a calibration gas flow rate of approximately 1000 cc/min (2.1 SCFH) is required. Flow rates lower than this may result in unstable readings, and higher flow rates may cause excessive cooling of the oxygen sensor.

Caution!

Do not use a calibration gas flow rate higher than

2000 cc/min (4.2 SCFH). Such flow rates will cool the

oxygen sensor and lead to inaccurate readings

or even cause damage to the sensor.

4-2 Calibration

Page 52

March 2006

) A

( T N

E R R

U C

T U

P T

U O

R = 5 R = 10 R = 25

0 5 10 15 20 25

PERCENT OXYGEN

Figure 4-1: Oxygen Sensor Calibration Output

Calibration 4-3

Page 53

March 2006

Calibrating the Oxygen Sensor

Calibrating with the Manual Switches

To calibrate the FGA 311’s oxygen sensor, either of the two programming methods described in Chapter 3, Operation and Programming, may be used. Proceed to the appropriate section for the chosen programming method.

Note: Make sure that the analyzer has been powered on and has

been allowed to warm up for at least one hour before attempting to calibrate the oxygen sensor.

To calibrate the analyzer with the manual switches located on the FGA 311 circuit board, complete the following steps:

Note: See Chapter 3, Operation and Programming, for general

information on using the manual switches.

1. Establish a flow of atmospheric

air into the calibration port for at least five minutes at a flow rate of 1000 cc/min (2 SCFH). This air may be obtained by tapping a line off the reference air source. See Figure 2-4 on page 2-10, for a suggested piping arrangement.

2. Perform an

a. Set

AIR calibration as follows:

Mode Switch S1 to position 1 (AIR) and wait for the output

reading to stabilize at 20.93%.

b. Push

CAL Switch S3 and hold until the green range LED’s

begin to blink (about five seconds).

c. When the green LED stops blinking (about 30 seconds), the

calibration is complete. Press

CAL Switch S3 and hold for

5 seconds (until the LED’s stop blinking) to EXIT programming mode.

d. Verify that the output reading of the analyzer indicates an

oxygen level of 20.93% ± 0.1%.

3. Stop the flow of atmospheric air to the calibration port and begin

the flow of the chosen calibration gas. Allow this flow to continue for at least five minutes at a flow rate of 1000 cc/min (2.1 SCFH).

4. Perform the

a. Set b. Push

GAS calibration as follows:

Mode Switch S1 to position 2 (GAS).

CAL Switch S3 and hold until the green range LED begins

to blink (about five seconds).

4-4 Calibration

Page 54

March 2006

Calibrating with the Manual Switches (cont.)

Calibrating with a PC Connection

c. Using ADJ Switch S2, adjust the output reading of the analyzer

to indicate the correct oxygen percentage within 0.1%, as described earlier in this chapter.

Note: After each adjustment, wait for the reading to stabilize before

performing any additional adjustments.

d. Press

CAL Switch S3 and hold for 5 seconds (until the LED’s

stop blinking) to EXIT programming mode.

5. Stop the flow of calibration gas to the unit.

The FGA 311 In Situ Flue Gas Oxygen Transmitter is now properly calibrated and ready for use.

To calibrate the analyzer with a personal computer (PC) connected via the RS232 port, complete the following steps:

Note: See Chapter 3, Operation and Programming, for general

information on using the PC connection.

1. Establish a flow of atmospheric

2. Perform an

a. Press b. Using the

highlighted and then press

c. Use the

[ENTER]. Wait for the reading to stabilize.

d. Press e. Press

AIR calibration as follows:

[ESC] to move from run mode to the User Program.

[SPACE] key if necessary, make sure OPTS is

[ENTER].

[SPACE] key to select the AIR option, and then press

[ENTER] to accept the new offset value.

[ESC] to leave the User Program and return to run mode.

3. Stop the flow of atmospheric air to the calibration port and begin

the flow of the chosen calibration gas. Allow this flow to continue for at least five minutes at a flow rate of 1000 cc/min (2.1 SCFH).

Calibration 4-5

Page 55

March 2006

Calibrating with a PC

4. Perform the GAS calibration as follows:

Connection (cont.)

a. Press b. Using the

c. Use the

d. Use the

Note: After each adjustment, wait for the reading to stabilize before

e. Press f. Press

5. Stop the flow of calibration gas to the unit.

The FGA 311 In Situ Flue Gas Oxygen Transmitter is now properly calibrated and ready for use.

[ESC] to move from run mode to the User Program.

[SPACE] key if necessary, make sure OPTS is

highlighted and then press

[SPACE] key to select the GAS option, and then press

[ENTER].

[+] and [–] keys to adjust the O2 value to correspond

[ENTER].

with the known oxygen content of the calibration gas.

performing any additional adjustments.

[ENTER] to accept the new oxygen value.

[ESC] to leave the User Program and return to run mode.

Resume Operation If a temporary calibration gas connection was made, disconnect the

calibration gas line and reinstall the plug on the calibration gas port. If a permanent calibration gas connection was installed, close the shut-off valve. Then, normal operation of the analyzer may be resumed.

4-6 Calibration

Page 56

Chapter 5

Page 57

Troubleshooting

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Sensor/Heater Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Temperature Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Output Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Oxygen Reading Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Page 58

March 2006

Introduction The FGA 311 In Situ Flue Gas Oxygen Transmitter has been designed

to overcome most of the problems commonly associated with monitoring flue gases. However, because of the corrosive and extreme conditions under which the instrument must operate, some difficulties may still be encountered. Procedures for resolving such situations are discussed in this chapter. If the required information can not be found in this chapter, contact the factory for assistance.

Two modes of error reporting have been built into the FGA 311 software:

• a fault indicator that is mounted on the printed circuit board

• an error message system that is accessible via the RS232 interface

Additional troubleshooting clues may be found by observing any unusual readings from the 4-20 mA output on terminal block TB2.

!WARNING!

To ensure safe operation of the FGA 311, the instrument

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.

The procedures in this manual should be performed only

by trained service personnel.

Troubleshooting Guide All of the most commonly encountered indicators of an operational

problem with the FGA 311 are listed in Table 5-1 on page 5-2. Refer to this table as the initial source of information regarding a specific problem. The table will indicate the location of a more detailed discussion of the problem and its solution.

IMPORTANT: This symbol indicates Caution - risk of electric

shock:

When working within the FGA 311 enclosure, be aware that full line voltage is present at terminal block TB1 on the printed circuit board, if the power is still applied to the unit. Be sure to observe any warnings noted in the individual troubleshooting sections of this chapter. Refer to Chapter 6, Service and Maintenance, for the location and/or replacement of any components mentioned during the troubleshooting procedure.

Troubleshooting 5-1

Page 59

March 2006

Table 5-1: Troubleshooting Guide

Problem Description Possible Cause(s) Go To:

ER2: “Warning: Warming Up!” replaces

“RUN” on the PC and the red fault LED flashes two times on the FGA 311

Temperature Problems

1. insufficient warm-up time allowed

2. defective heater or thermocouple

3. defective wiring or PC board

page 5-4

ER3: “Open Thermocouple!” replaces “RUN” on the PC and the red fault LED flashes

1. defective thermocouple

2. defective wiring or PC board

three times on the FGA 311 ER4: “Heater Failure!” replaces “RUN” on the

PC and the red fault LED flashes four times

1. defective heater

2. defective wiring or PC board

on the FGA 311

Output Problems

no response from the FGA 311 (4-20 mA, RS232 and PC Board LEDs show no output)

1. no power to unit

2. blown fuse

3. defective PC board

no RS232 output, but the PC board LEDs and the 4-20 mA output are active

1. defective wiring

2. defective EPROM

Oxygen Reading Problems

ER1: “Sensor Failure!” replaces “RUN” on the

PC and the red fault LED glows constantly on the FGA 311

1. defective oxygen sensor

2. wiring problem

3. defective PC board

percent oxygen always reads 20.93% 1. air leak in plumbing

2. defective wiring or PC board

percent oxygen is stuck on same reading for more than 15 minutes

1. display left in

2. clogged filter

FREEZE mode

page 5-5

page 5-6

page 5-7

page 5-8

page 5-9

page 5-10

page 5-11

oxygen reading is lower than expected 1. combustibles in sample gas page 5-11 oxygen reading is higher than expected 1. leak in plumbing page 5-11

5-2 Troubleshooting

Page 60

March 2006

Sensor/Heater Wiring As an aid in following the troubleshooting procedures described in

this chapter, the wiring connections for the FGA 311 sensor/heater sub-assembly are shown in Figure 5-1 below.

Pin #

1 2 3 4 5 6

Color

Black

Pink

Yellow

Red Red Red

6 5 4 3 2 1

Description

O2 (-) O2 (+) TC (+) TC (-)

Heater Heater

6 5 4 3 2 1

Figure 5-1: Sensor/Heater Connections

Temperature Problems If the FGA 311 has difficulty in achieving or maintaining the normal

operating temperature of 700°C, the problem will be indicated in two

ways:

• the red fault LED located on the printed circuit board will begin to

flash

• if the FGA 311’s RS232 interface is connected to a computer, the

standard measurement screen will show one of the built-in error messages.

Proceed to the appropriate sub-section for detailed information on specific temperature problems.

Troubleshooting 5-3

Page 61

March 2006

ER2 Error Code When the ER2 error code is generated, the red fault LED on the

printed circuit board will begin to flash in groups of two flashes each and the following message screen will be sent to the computer via the RS232 interface:

ER2 20.93% O2 700.0C

ER2 replaces RUN on the measurement mode screen.

Although as long as three hours may be required to achieve a stable output, the FGA 311 should reach normal operating temperature in about 30 min. When the proper operating temperature has been reached, the

ER2 error message is replaced by the normal

measurement screen.

Note: The actual

Warning: Warming Up! message only appears on the

multi-line diagnostic PC screen.

If this message is displayed on the screen, complete the following troubleshooting steps:

1. Allow at least thirty minutes for the unit to warm up. If the

ER2

error message persists beyond the 30-minute warm-up time, proceed to step 2.

2. Usually, a defective heater or thermocouple will generate its own

error message. However, it is helpful to verify the integrity of these components now by completing the following steps:

!WARNING!

Disconnect the main power from the unit and allow at least

two hours for the system to cool down before proceeding

with the following steps.

a. Pull the connector from the end of the sensor/heater sub-

assembly. Using a digital multimeter, measure the resistance between the two heater connections (pins 5 and 6, on the sensor/heater assembly. The reading should be about 375 ohms for a 110 VAC heater or 1,180 ohms for a 220 VAC heater. If the reading is significantly higher, the heater is defective and the sensor/heater sub-assembly must be replaced (see “Sensor/ Heater Sub-Assembly Replacement” on page 6-5).

IMPORTANT: Do not

measure the heater resistance on the loose connector, which contains the wires going to the PC board.

b. If the heater appears to be good, reinstall the connector on the

end of the sensor/heater sub-assembly and proceed to step 3.

5-4 Troubleshooting

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March 2006

ER2 Error Code (cont.) 3. If sufficient warm-up time has been allowed and the heater is

good, then the problem is the result of faulty wiring or a defective printed circuit board. Proceed as follows:

a. Refer to Chapter 2, Installation, including the wiring diagram

in Figure 2-3, and to Figure 5-1 on page 5-3. Make sure that all of the wires have been connected to the proper terminal blocks. Also, carefully inspect the wiring for shorts and be certain that all of the cable connectors are properly seated in their terminal blocks. Lastly, verify that each individual lead is still firmly seated in its connector.

b. If no wiring problems were discovered in the step above, the

circuit board is defective and it must be replaced (see “Printed Circuit Board Replacement” on page 6-7).

ER3 Error Code When the ER3 error code is generated, the red fault LED on the

printed circuit board will begin to flash in groups of three flashes each and the following message screen will be sent to the PC via the RS232 interface:

ER3 20.93% O2 700.0C

ER3 replaces RUN on the measurement mode screen.

Note: The actual

Open Thermocouple message will appears on the

multi-line diagnostic PC screen.

If this message is displayed on the screen, complete the following troubleshooting steps:

!WARNING!

Disconnect the main power from the unit and allow at least

two hours for the system to cool down before proceeding

with the following steps.

1. Pull the connector from the end of the sensor/heater sub-assembly.

Using a digital multimeter, measure the resistance between the two thermocouple leads (pins 3 and 4, on the sensor/heater assembly). If the reading indicates an open circuit, the thermocouple is defective and the sensor/heater sub-assembly must be replaced (see “Sensor/Heater Sub-Assembly Replacement” on page 6-5). If the thermocouple does not show an open circuit, proceed to step 2.

Troubleshooting 5-5

Page 63

March 2006

ER3 Error Code (cont.) IMPORTANT: Do not measure the thermocouple resistance on the

loose connector, which contains the wires going to the PC board.

2. If the thermocouple is good, then the problem is the result of

faulty wiring or a defective printed circuit board.

a. Refer to Chapter 2, Installation, including the wiring diagram

b. If no wiring problems were discovered above, the circuit board

is defective and it must be replaced (see “Printed Circuit Board Replacement” on page 6-7).

ER4 Error Code When the ER4 error code is generated, the red fault LED on the

printed circuit board will begin to flash in groups of four flashes each and the following message screen will be sent to the PC via the RS232 interface:

ER4 20.93% O2 700.0C

ER4 replaces RUN on the measurement mode screen.

Note: The actual

Heater Failure! message only appears on the multi-

line diagnostic PC screen.

If this message is displayed on the screen, complete the following troubleshooting steps:

!WARNING!

Disconnect the main power from the unit and allow at least

two hours for the system to cool down before proceeding

with the following steps.

1. Pull the connector from the end of the sensor/heater sub-assembly.

Using a digital multimeter, measure the resistance between the two heater connections (pins 5 and 6, on the sensor/heater subassembly). The reading should be about 375 ohms for a 110 VAC heater or 1,180 ohms for a 220 VAC heater. If the reading is significantly higher than this, the heater is defective and the sensor/heater sub-assembly must be replaced (see “Sensor/Heater Sub-Assembly Replacement” on page 6-5).

5-6 Troubleshooting

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March 2006

ER4 Error Code (cont.) IMPORTANT: Do not measure the thermocouple resistance on the

loose connector, which contains the wires going to the PC board.

2. If the heater appears to be good, reinstall the connector on the end

of the sensor/heater sub-assembly. The problem is likely the result of faulty wiring or a defective printed circuit board, and the following steps should be completed.

a. Refer to Chapter 2, Installation, including the wiring diagram

b. If no wiring problems were discovered in the step above, the

circuit board is defective and it must be replaced (see “Printed Circuit Board Replacement” on page 6-7).

Output Problems If one or more of the analyzer’s outputs is completely non-functional,

proceed with the instructions in this section.

All Outputs Inactive If the analyzer is completely inactive (i.e. there is no RS232 or 4-20

mA signal output and all of the LEDs on the printed circuit board are off), there is a power failure in the system. Proceed as follows:

IMPORTANT: This symbol indicates Caution - risk of electric

shock:

1. Check the input power to the PC board as follows:

a. Remove the plastic cover from the fuse holder. b. Use a digital AC voltmeter to check the power into the printed

circuit board. Place one of the voltmeter leads on the ground terminal inside the FGA 311 enclosure and place the other voltmeter lead on the end of the fuse holder closest to terminal block TB1 on the printed circuit board.

c. The above test point is the direct input line to the printed circuit

board, and full line voltage should be present there. If there is no voltage at that point, check the power source, the main disconnect and the connections to terminal block TB1.

d. If there is full line voltage reaching the PC board, proceed to

the next step.

Troubleshooting 5-7

Page 65

March 2006

All Outputs Inactive (cont.) 2. Check the fuse as follows:

a. Place one of the voltmeter leads on the ground terminal inside

the FGA 311 enclosure and place the other voltmeter lead on the end of the fuse holder farthest from terminal block TB1 on the printed circuit board.

b. If full line voltage is not present at the above test point, the fuse

is defective and must be replaced (see “Fuse Replacement” on page 6-3).

c. If there is full line voltage at the test point, proceed to the next

step.

3. The presence of full line voltage at both ends of the fuse holder

indicates that the proper power is reaching the printed circuit board. Therefore, the printed circuit board is defective and must be replaced (see “Printed Circuit Board Replacement” on page 6-7).

No RS232 Output If the analyzer is operating normally, but the RS232 interface is not

functioning, proceed with the following steps:

1. Carefully inspect the RS232 cable connections within the FGA

311’s enclosure. Make sure there are no shorts caused by faulty wiring at the connector to terminal block TB2 on the printed circuit board. Also, verify that positive contact is being made by the leads to pins 1-3 of this terminal block. If these connections are secure, proceed to the next step.

2. At the PC end of the RS232 cable, make sure that the DB9

connector is securely installed on the serial port of the computer. Refer to the computer’s documentation and the FGA 311’s RS232 interface parameters (see “RS232 Serial Port Settings” on page 3-

9). If the RS232 interface has been properly established, in accordance with these requirements, proceed to the next step.

Note: Frequently, reversing leads 2 and 3 of the RS232 connection

on terminal block TB2 will solve this type of problem.

3. The EPROM is defective and must be replaced (see “EPROM

Replacement” on page 6-9).

5-8 Troubleshooting

Page 66

March 2006

Oxygen Reading Problems

The generation of inaccurate oxygen readings by the FGA 311 will be

indicated in two ways:

• the red fault LED located on the printed circuit board will begin to

flash and the ER1 error code will be generated on a PC that is connected via the RS232 serial port.

• unusual or unexpected oxygen percentages will be read at the

4-20 mA output terminals (pins 4-5) on terminal block TB2.

Proceed to the appropriate sub-section for detailed information on specific oxygen reading problems.

ER1 Error Code When the ER1 error code is generated, the red fault LED on the PC

board flashes in groups of one flash each and the following message screen will be sent to the PC via the RS232 interface:

ER1 20.93% O2 700.0C

Note: The actual

line diagnostic PC screen.

Sensor Failure! message only appears on the multi-

ER1 replaces RUN on the

measurement mode screen.

If this message is displayed on the screen, complete the following troubleshooting steps:

!WARNING!

Disconnect the main power from the unit and allow at least

two hours for the system to cool down before proceeding

with the following steps.

1. Check the oxygen sensor as follows:

a. Remove the electrical connector from the end of the sensor/

heater sub-assembly (see Figure 5-1 on page 5-3).

b. Using a digital multimeter, measure the resistance between the

oxygen sensor connections (pins 1 and 2, on the sensor/heater sub-assembly connector).

IMPORTANT: Do not

loose connector, which contains the wires going to the PC board.

measure the oxygen sensor resistance on the

Troubleshooting 5-9

Page 67

March 2006

ER1 Error Code (cont.) c. If the reading indicates an open circuit, the oxygen sensor is

defective and the entire sensor/heater sub-assembly must be replaced (see “Sensor/Heater Sub-Assembly Replacement” on page 6-5).

d. If the oxygen sensor is good, reinstall the connector on the end

of the sensor/heater sub-assembly and proceed to step 2.

2. Check the wiring and the printed circuit board as follows:

a. Carefully inspect the connector at terminal block J2 on the

printed circuit board for shorts and/or wires that are not securely seated in the connector. Pay particular attention to the oxygen sensor leads at pins 3-4 of this connector.

b. Carefully inspect the connector on the end of the sensor/heater

sub-assembly for shorts and/or wires that are not securely seated in the connector. Pay particular attention to the oxygen sensor leads at pins 1-2 of this connector.

c. If no wiring problems were discovered in the step above, the

circuit board is defective and must be replaced (see “Printed Circuit Board Replacement” on page 6-7).

Oxygen Percentage Always Reads 20.93

This condition is somewhat unusual, and it is probably caused by a leak in the plumbing, a defect in the printed circuit board, or defective wiring. To isolate the problem, complete the following steps:

1. A leak in the plumbing may cause the reference air to become

contaminated with the process flue gases. When the zirconium oxide oxygen sensor has the same oxygen content on both sides of the cell, its output will be 0.0 mV, which will generate a 4-20 mA signal that converts to 20.93% oxygen. Find and correct any plumbing leaks that could cause the above contamination to occur. If the problem persists, proceed to the next step.

2. Check for shorts in the oxygen sensor wiring at pins 1 and 2 on the

sensor/heater sub-assembly connector and at pins 3 and 4 of terminal block J2 on the printed circuit board.

3. If no plumbing leaks or oxygen sensor wiring shorts were found,

remove the connector from the end of the sensor/heater subassembly. Using a digital voltmeter, measure the voltage across pins 1 (-) and 2 (+) on the sensor/heater sub-assembly (not the loose connector). If this voltage is 0.0 mV, the 20.93% oxygen reading is valid. If some non-zero voltage is read, the printed circuit board is defective and must be replaced (see “Printed Circuit Board Replacement” on page 6-7).

5-10 Troubleshooting

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March 2006

Oxygen Percentage Unchanged for more than 15 Minutes

Oxygen Reading Lower Than Expected

It is possible that the flue gas composition really is this stable. However, if such is not the case, there are two likely causes for this problem.

1. The analyzer may have accidentally been left in

Refer to Chapter 3, Operation and Programming, and select the

UNFREEZE option from the EXTRA menu. If the unit was not in FREEZE mode, proceed to the next step.

2. The porous filter on the end of the probe assembly may have

become clogged. If this is the case, the probe tip will have to be cleaned or replaced (see “Probe Tip Replacement” on page 6-1).

The zirconium oxide oxygen sensor will respond to combustibles such as CO, H

generating several millivolts of additional voltage output. Although the FGA 311 will accurately process this information, the resulting oxygen reading will be lower than expected. Some possible sources of such contamination are:

or other hydrocarbons in the sample gases by

FREEZE mode.

• oil or grease in the plumbing system

• pipe thread compound on the fittings

Oxygen Reading Higher Than Expected

• oil or grease on the oxygen sensor due to handling the sensor with

bare hands

• excess fuel in the burner.

Resolve the problem be finding and eliminating the source of the contaminating combustibles.

The likely cause of an oxygen reading that is higher than expected is a gas leak that permits the reference air to become contaminated with the process flue gases. This contamination will lower the millivolt output of the zirconium oxide oxygen sensor, and the 4-20 mA output signal will indicate an oxygen percentage that is higher than expected.

Although the FGA 311 will accurately process this information, the result will not reflect the actual oxygen content of the flue gases. To correct the problem, find and correct any plumbing leaks that could cause the above contamination to occur.

Troubleshooting 5-11

Page 69

Chapter 6

Page 70

Service and Maintenance

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Probe Tip Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Cover Removal and Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Sensor/Heater Sub-Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-5

Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

EPROM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Page 71

March 2006

Introduction Although the FGA 311 has been engineered for long, trouble-free

service, some components may require occasional replacement. The FGA 311 has been designed for quick and easy field replacement of these components, when it does become necessary.

Probe Tip Replacement The only field-replaceable external component of the FGA 311 is the

probe tip. The probe tip may become clogged or cracked over time and require cleaning or replacement. If this is the case, refer to Figure 6-1 below and complete the following steps:

1. Power down the unit and allow approximately two hours for it to

cool down to ambient temperature.

!WARNING!

Disconnect the main power from the unit and allow at least

two hours for the system to cool down before proceeding

with the following steps.

3/4" NPT Thread

Probe Base

2. Disconnect all electrical and mechanical lines from the analyzer.

3. Remove the unit from the flue. See Chapter 2, Installation, for

details on mounting the analyzer to the flue wall.

4. Unthread the existing probe tip from the end of the probe base.

5. Either clean the existing probe tip or, if it is damaged, secure a

replacement.

Note: Do not use a thread sealant on the probe threads. However, a

dry, high-temperature, graphite-based lubricant may be used.

Probe Tip

(for 19" probe)

Figure 6-1: Probe Tip Replacement

Service and Maintenance 6-1

Page 72

March 2006

Filter Replacement (cont.)

Cover Removal and Reinstallation

6. Apply the thread lubricant to the probe threads and securely

tighten the probe tip onto the end of the probe base.

7. Reinstall the FGA 311 into the flue wall. See Chapter 2,

Installation, for specific instructions.

8. Reconnect all electrical and mechanical lines to the analyzer body.

9. Apply power to the unit and let it heat back up to the normal

operating temperature of 700°C. This should take approximately

thirty minutes.

Normal operation of the FGA 311 may now be resumed.

All other field-replaceable components are located within the FGA 311’s enclosure, and the unit need not be removed from the flue stack to service these items. The first step in replacing these parts is to remove the cover from the enclosure. Refer to Figure 6-2 below and complete the following steps:

Slot

O-Ring

Ground Screw

s :

M a d e i

n U S A

Cover

Set Screw

Figure 6-2: Cover Removal

Enclosure

6-2 Service and Maintenance

Page 73

March 2006

Cover Removal and Reinstallation (cont.)

1. Loosen (do not remove) the locking set screw that is located near

one of the slots on the cover.

IMPORTANT: These symbols indicate Caution - dangerously hot

surfaces and risk of electric shock, respectively:

2. Place a large screwdriver or similar tool across the two slots

located on the cover. Using the screwdriver as a lever, begin to rotate the cover in a counterclockwise direction. Once the cover has been loosened, continue to unthread it by hand and pull the cover away from the enclosure.

3. Complete whatever maintenance is required within the enclosure,

as instructed later in this chapter.

4. Make sure that the o-ring is still in place on the cover, and thread

the cover back into the enclosure. Using the large screwdriver across the slots, tighten the cover securely.

5. Lock the cover in place by tightening the set screw located near

one of the slots.

The FGA 311 may now be placed back into service.

Fuse Replacement To replace the fuse in the FGA 311, refer to Figure 6-3 on page 6-4

and complete the following steps:

1. Disconnect the main power from the analyzer.

!WARNING!

Disconnect the main power from the unit and allow at least

two hours for the system to cool down before proceeding

with the following steps.

2. Remove the cover from the enclosure, as described above.

3. Pull the soft plastic protective cover off the fuse holder.

4. Pull the fuse out of its holder and replace it with a new fuse. See

Chapter 7, Specifications, for the correct fuse to use.

5. Reinstall the protective plastic cover over the fuse holder.

6. Reinstall the cover, as described above. Power up the unit and

allow it to warm up for at least one hour.

Service and Maintenance 6-3

Page 74

March 2006

Power Leads

Fuse

Fuse Cover

Heater Leads

Standoff

Thermocouple Leads

RS232 Leads

Sensor/Heater Connector

Gas Hose

U 1 8

2 E

3 1 F

3 J

1 4

3 E

1 T

3 1

W 5

1 5

C 2

VR2

5 1 U

6 1 C

6 E

2 J

R34

E D

L A C

1 E

5 E

7 E

Standoff

W 1

1 1 E

T L

DS4

U A F

8 E

1 S

3 S

6 1 2 1

0 7

5 2

DS3

0 1

DS2 DS1

2 S

J D A

Sensor/Heater Assy.

Sensor Leads

END VIEW

4-20 mA Leads

Standoff

Gas Hose

Sensor/Heater Connector

SECTION

SIDE VIEW

Figure 6-3: Internal View of Enclosure

6 5 4 3 2 1

TB1

Standoff

EPROM

Sensor/Heater Assy.

J2 PC Board

TB2

6-4 Service and Maintenance

Page 75

March 2006

Sensor/Heater SubAssembly Replacement

Removing the Sensor/ Heater Sub-Assembly

If either the heater, the thermocouple or the oxygen sensor becomes defective, the sensor/heater sub-assembly must be replaced. To do so, refer to Figure 6-3 on page 6-4 and proceed to the next section.

IMPORTANT: Never disassemble or attempt to repair the sensor/

heater sub-assembly in the field. The entire subassembly must be replaced as a complete unit.

Remove the defective sensor/heater sub-assembly as follows:

1. Power down the FGA 311 and allow at least two hours for the unit

to cool down to ambient temperature. Remove the cover from the enclosure, as described on page 6-3.

!WARNING!

Disconnect the main power from the unit and allow at least

two hours for the system to cool down before proceeding

with the following steps.

2. Pull the 1/8” black calibration gas hose off the calibration gas

fitting on the sensor/heater sub-assembly.

3. Pull the 6-wire connector off the end of the sensor/heater sub-

assembly.

4. Grasp the black plastic block at the end of the sensor/heater sub-

assembly, and turn it counterclockwise until it comes free from the threads in the base of the enclosure.

Caution!

The exposed ends of the oxygen cell are easily damaged

if they strike a hard surface.

Also, do not handle the exposed ends of the oxygen cell

with bare fingers, as deposits of skin oils and/or salts

may seriously impair the sensor’s operation.

5. Carefully, pull the sensor/heater sub-assembly straight out of the

enclosure.

Proceed to the next section for instructions on installing the sensor/ heater sub-assembly.

Service and Maintenance 6-5

Page 76

March 2006

Installing the Sensor/ Heater Sub-Assembly

Refer to Figure B-4 in Appendix B, for an illustration of the sensor/ heater sub-assembly. To install the new assembly, refer to Figure 6-3 on page 6-4 and complete the following steps:

1. Carefully, slide the sensor/heater sub-assembly straight into the

opening at the base of the enclosure.

Caution!

The exposed ends of the oxygen cell are easily damaged, if they strike a hard surface. Also, do not handle the exposed

ends of the oxygen cell with bare fingers, as deposits of

skin oils and/or salts may seriously impair the sensor’s

operation.

2. Grasp the black plastic block at the end of the sensor/heater sub-

assembly, and screw the assembly into the threads at the base of the enclosure. Proper tightening of the assembly requires that it be turned clockwise until it is hand-tight and then turned an additional 1/4 turn.

3. Attach the 6-wire connector to the end of the sensor/heater sub-

assembly.

4. Push the 1/8” black calibration gas hose onto the calibration gas

fitting on the sensor/heater sub-assembly.

5. Reinstall the cover on the enclosure, as described on page 6-3, and

power up the FGA 311.

After the unit has heated up to its normal operating temperature of 700°C (about thirty minutes), data taking may be resumed.

6-6 Service and Maintenance

Page 77

March 2006

Printed Circuit Board Replacement

Removing the Printed Circuit Board

If the printed circuit board becomes defective, replace it by referring to Figure 6-3 on page 6-4 and completing the steps that follow.

Remove the defective printed circuit board as follows:

1. Power down the FGA 311 and allow at least two hours for the unit

to cool down to ambient temperature. Remove the cover from the enclosure, as described on page 6-3.

!WARNING!

Disconnect the main power from the unit and allow at least

two hours for the system to cool down before proceeding

with the following steps.

2. Remove the sensor/heater sub-assembly, as described on page 6-5.

3. Pull the 3-wire connector off terminal block J3 and the 6-wire

connector off terminal block J2, on the printed circuit board. Remove the sensor/heater cable assembly from the enclosure.

4. Disconnect all ground leads from the two grounding lugs on the

inside of the FGA 311’s enclosure.

5. Pull the 2-wire line power connector from terminal block TB1 on

the PC board. In a similar manner, pull the 5-wire control signal connector from terminal block TB2 on the PC board.

6. Using a 1/4” nutdriver, remove the two standoffs that secure the

printed circuit board to the bottom of the enclosure.

7. Carefully pull the printed circuit board out of the enclosure. It will

be necessary to angle the board slightly to work it past the two grounding lugs on the sides of the enclosure.

Service and Maintenance 6-7

Page 78

March 2006

Installing the Printed Circuit Board

Refer to Figure B-3 in Appendix B, for an illustration of the printed circuit board. To install the new printed circuit board, refer to Figure 6-3 on page 6-4 and completing the following steps:

1. With the component side facing away from the enclosure, insert

the PC board into the enclosure. Angle the board as required to get it past the two grounding lugs on the sides of the enclosure.

2. Secure the printed circuit board to the base of the enclosure by

installing the two standoffs with a 1/4” nutdriver.

IMPORTANT: The printed circuit board may be installed in two

different orientations that are rotated 180° from each

other. Orient the board so that the fuse is located near the power cable.

3. Plug the power connector and the control signal connector into

terminal block TB1 and terminal block TB2 on the printed circuit board, respectively. These connectors are polarized and can only be inserted into the terminal blocks in the proper orientation.

4. Reconnect all ground leads to the two grounding lugs on the inside

of the enclosure.

5. Reinstall the sensor/heater cable assembly by connecting the

3-wire connector to terminal block J3 and the 6-wire connector to terminal block J2, on the printed circuit board.

6. Install the sensor/heater sub-assembly, as described on page 6-6.

7. Reinstall the cover on the enclosure, as described on page 6-3, and

power up the FGA 311.

After the unit has heated up to its normal operating temperature of 700°C (about thirty minutes), data taking may be resumed.

6-8 Service and Maintenance

Page 79

March 2006

EPROM Replacement To permit software upgrades and to allow replacement of a damaged

EPROM, the EPROM chip (U3) has been socketed on the solder side of the printed circuit board. Refer to Figure 6-4 below and complete the following steps to replace the EPROM:

CR4

U10

7 1 U

5 C

C34

2 1 R

U11

R10

C30

C23

C17

3 3 R

C29

C28

C25

R21

1 1 C

R4 R3

C10

R13

C36

C12

4 1

VR1

C31

1 C

5 1

C19

5 2

U13

4 2

1 R

C35

7 1 R

EPROM

Notch

CR3

7 2 R

U14

8 2 R

XU3

R32

1 3 R

C37

C24

0 3 R

R29

C27

Figure 6-4: Solder Side of PC Board

1. Power down the FGA 311 and allow at least two hours for the unit

to cool down to ambient temperature. Remove the cover from the enclosure, as described on page 6-3.

!WARNING!

Disconnect the main power from the unit, and allow

at least two hours for the system to cool down,

before proceeding with the following steps.

2. Remove the printed circuit board, as described on page 6-7.

3. Turn the printed circuit board over to the solder side and locate the

socketed EPROM (U3). Using the end of a paper clip or similar object, carefully pry the EPROM (U3) out of its socket. Pry the chip out evenly by lifting it a little at a time at each of the four corners, in sequence.

Service and Maintenance 6-9

Page 80

March 2006

EPROM Replacement (cont.)

Remove the new EPROM from its anti-static packaging, and install it by completing the following steps:

Caution!

The EPROM is easily damaged by static electricity.

Before handling the chip, touch an earth ground to

discharge any static electricity and install a grounding

strap on your wrist. Also, avoid touching the pins on the

EPROM with bare fingers, as skin oils can prevent proper

electrical contact with the socket.

1. Align the notch on the EPROM with the notch on its socket, and

firmly press the EPROM into the socket on the printed circuit board until it is evenly and completely seated.

2. Reinstall the PC board, as described on page 6-8.

3. Reinstall the cover on the enclosure, as described on page 6-3, and

power up the FGA 311.

After the unit has heated up to its normal operating temperature of 700°C (about thirty minutes), data taking may be resumed.

6-10 Service and Maintenance

Page 81

March 2006

Spare Parts List The components necessary to maintain and repair the FGA 311 are

readily available from the factory. The descriptions and part numbers for the major components are listed in Table 6-1 below.

Table 6-1: Spare Parts List

Description Part No. Qty. Notes

PC Board 703-1216 1 ------

EPROM 707-247 1 -----Fuse (1/4 A) 193-054-03 1 for 115 VAC Fuse (1/2 A) 193-054-04 1 for 230 VAC

Sensor/Heater Assy 705-765-02 1 115 VAC Sensor/Heater Assy 705-765-03 1 230 VAC

19” Probe Tip 705-800-02 1 Normal Temp. 19” Probe Tip 705-800-03 1 High Temp. 19” Probe Tip 422-011-01 1 XP, Normal Temp. 19” Probe Tip 422-011-02 1 XP, High Temp.

1m Probe Tip 422-034-01 1 316SS, Normal Temp. 1m Probe Tip 422-034-02 1 Inconel, High Temp.

1.5m Probe Tip 422-034-03 1 316SS, Normal Temp.

1.5m Probe Tip 422-034-04 1 Inconel, High Temp. 2m Probe Tip 422-034-05 1 316SS, Normal Temp. 2m Probe Tip 422-034-06 1 Inconel, High Temp.

To purchase replacement parts, have the serial number of the unit available and contact GE Sensing for assistance.

Service and Maintenance 6-11

Page 82

Chapter 7

Page 83

Specifications

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Physical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Page 84

Performance Accuracy:

March 2006

3% of reading or 0.1% O

Measurement Resolution:

Output 4–20 mA: 0.01 mA

RS232 Terminal Interface:

0.01% O

Response Time:

Less than 5 seconds for 63% of step change

Measurement Range:

Fully field-selectable via RS232 interface or on-board switches 0–5% O

0–10% O

0–25% O

Operation Process Temperature:

Standard: 150 ° to 650°C (300° to 1200°F)

High Temperature: 150° to 1050°C (300° to 1920°F)

Ambient (Electronics) Temperature:

–20° to 70°C (–4° to 160°F)

Calibration Methods:

Semi-automatic by push-button RS232 interface Digipot adjustment

Recommended Calibration Gas Mixture:

Zero Gas: 5.0% O

, balance N

(depends on application and range) Span Gas: 20.93% O

, balance N

Flow Rate: 2,000 cc/min (4 SCFH)

Reference Air:

Composition: instrument air (20.93% O

regulated to 3 psi (20 kPa) Flow Rate: 20 to 50 cc/min (0.04 to 0.11 SCFH)

Specifications 7-1

Page 85

March 2006

Functional Output:

4–20 mA Analog Output: isolated, 600 ohm maximum Digital Output: RS232 communications

Power Input:

115 VAC 230 VAC,

Power Consumption:

75 W

Process Connection:

Standard: 1½” NPTM Optional: 2” and larger flanges

Physical Materials:

Enclosure: Epoxy-coated aluminum Probe: Process wetted or welded parts

Standard temperature: 316 SS High temperature: Inconel® alloy

Probe Lengths:

19 inch probe 1 meter probe

1.5 meter probe 2 meter probe

Probe Weight:

19” probe = 6.8 kg (15 lb)

Probe Mounting:

Orientation: vertical or horizontal, 1 1/2” NPT Type: flange (available in most common sizes)

7-2 Specifications

Page 86

Physical (cont.) Hazardous Area Certifications:

Weatherproof: NEMA-4X, IP66 Explosion-proof / Flameproof:

C_US Certification No. 1622936 Class I, Div. 1, Groups B, C, D T6 (electronic housing) T4 (sensor probe) ISSeP02ATEX028 X, Electronics: II 2 GD EEx d IIB T6 ISSeP02ATEX028 X, Process: II 2 GD d IIB T2

European Compliance:

Complies with EMC Directive 89/336/EEC and 73/23/EEC LVD (Installation Category II, Pollution Degree 2) and PED 97/23/EC

March 2006

for DN<25.

Specifications 7-3

Page 87

Appendix A

Page 88

The Nernst Equation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equilibrium Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

The FGA 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Page 89

March 2006

Introduction The FGA 311 In Situ Flue Gas Oxygen Transmitter uses the Nernst

Equation to calculate the oxygen content of the flue gas. When a

Yttrium-doped zirconium oxide ceramic is heated to a temperature above 650°C

, it becomes an electrolytic conductor as vacancies in the

crystal lattice permit oxygen ions to diffuse into the ceramic.

If there are different oxygen partial pressures on the two sides of the ceramic cell, oxygen ions will migrate along the resulting concentration gradient. This constitutes a transfer of electrons from one face of the ceramic to the other. If the transferred charge is allowed to accumulate, it gives rise to a potential gradient acting in the opposite direction, thus tending to oppose further diffusion.

Equilibrium Conditions Under equilibrium conditions, the potential gradient exactly balances

the concentration gradient. Porous coatings of a platinum catalyst on both surfaces of the ceramic cell serve as electrodes, while still allowing the oxygen molecules to penetrate the coating and diffuse into the ceramic. The measured voltage drop across the cell can be directly related to the ratio of the two oxygen partial pressures by means of Equation A-1, the Nernst Equation, below:

-------nF

-----

ln•=

where,

F = the Faraday = 96,484.56 coulombs T = absolute temperature = °K R = gas constant = 8.31441 volt-coulomb/mole- °K n = # electrons transferred per molecule = 4/mole ln = natural logarithm = 2.303 log

p1 = O2 partial pressure on reference gas side = 0.2093

= O2 partial pressure on flue gas side

= voltage on reference face with respect to the flue gas face

(0-1)

The Nernst Equation A-1

Page 90

March 2006

The FGA 311 The Nernst Equation specifically applicable to the FGA 311 analyzer

is obtained by substituting the above values into the general equation, converting the natural logarithm to the common logarithm (base 10) and converting the units for E

A-2 below.

mV( ) 0.049605 T•

The FGA 311 measures the temperature at the sensor and automatically inserts the correct value into the Nernst Equation. For example, at the usual operating sensor temperature of 700°C,

Equation A-3 below is used.

E12mV( ) 48.274

The voltage drop across the zirconium oxide sensor, as calculated from the Equation A-3 above, is then sent to the linearizer circuit. This circuit produces a linear 4-20 mA output that represents the percentage of oxygen in the flue gas, and this signal is available to the user at pins 4-5 of terminal block TB2 on the printed circuit board.

to millivolts. This results in Equation

0.2093

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

log•=

0.2093

---------------p

(0-2)

(0-3)

A-2 The Nernst Equation

Page 91

Appendix B

Page 92

FGA 311 Drawings

FGA 311 Assembly (Weatherproof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

FGA 311 Assembly (Explosion-Proof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

FGA 311 Printed Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

FGA 311 Heater Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

RS232 Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Page 93

March 2006

Figure B-1: FGA 311 Weatherproof Assembly (Drawing 705-764, Sheet 1)

FGA 311 Drawings B-1

Page 94

March 2006

PANAMETRICS

Figure B-2: FGA 311 Explosion-Proof Assembly (Drawing 705-764, Sheet 2)

FGA 311 Drawings B-2

Page 95

CAL

March 2006

U15

VR2

U19

E10

R34

TB2

MODE

ADJ

51025

DS2

DS1

FAULT

DS3

DS4

E11 E12

W2 W1

703-1216

TB1

W5W6

RT1

C14

CR3

R27

R28

R26

R32

C26

XU3

R31

R29

C37

C24

R30

C15C16

U18

DS5

U14

CR4

U10

R11

U17

C30 C23

C29

U11

R10

C17

R33

R4 R3 R2

C28

R12

C10

R13

C11

C12

VR1

C31

U12

R23

C21R7

C36

R22

C22

C32

U16

R25

R24

R20

C19

C20 R16

R17

U13

R14

C18

R15

C35

C33

R19

R18

C27

C25

C34

R21

Figure B-3: FGA 311 Printed Circuit Board

COMPONENT SIDE SOLDER SIDE

FGA 311 Drawings B-3

Page 96

March 2006

Figure B-4: FGA 311 Heater Assembly (Drawing 705-766)

FGA 311 Drawings B-4

Page 97

March 2006

Figure B-5: RS232 Cable Assembly (Drawing 704-668)

FGA 311 Drawings B-5

Page 98

Appendix C

Page 99

CE Mark Compliance

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

EMC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

LVD Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Page 100

March 2006

Overview For CE Mark compliance, the analyzer must meet both the EMC and

LVD directives.

IMPORTANT: CE Mark compliance is required only for units used

in EEC countries.

EMC Compliance For EMC compliance, the electrical connections must be shielded and

grounded as shown in Table C-1 below. After all the necessary electrical connections have been made, seal unused cable entry holes with standard conduit plugs or equivalent.

Note: If the instructions in this appendix are followed, your unit will

comply with the EMC Directive 89/336/EEC.

Table C-1: Wiring Modifications for EMC Compliance

Connection Wiring Modification

1. When connecting the power, select the cable entry closest to the chassis ground.

Power

Input/Output

2. Use shielded cable* to connect the power to the FGA311 enclosure. Connect the shield to the nearest chassis ground terminal.

3. Connect the power line ground wire to the nearest chassis ground terminal.

1. Use shielded cable* to interconnect the FGA 311 enclosure with any external I/O devices.

2. Connect the shields to the nearest chassis ground terminal.

*Wires enclosed in a properly-grounded metal conduit do not

require additional shielding.

LVD Directive For compliance with the European Union’s LVD, the analyzer

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 FGA 311. It must be clearly marked as being the disconnect device for the analyzer.

Note: If the instructions in this appendix are followed, your unit will

comply with the Low Voltage Directive 73/23/EEC with the following exception: the 230 VAC unit passes with a test voltage of 1,800 VAC (refer to Table D.10 of Annex D in EN61010).

CE Mark Compliance C-1