Super Systems Basic Nitriding Sampling System Operations Manual

Basic Nitriding Sampling System

Hydrogen Analyzer with Calculated % DA,

% NH

3,

and K

N

Values

PN: 13537

Operations Manual

Please read, understand, and follow these instructions before operating this equipment.

Super Systems, Inc. is not responsible for damages incurred due to a failure to comply with these

instructions. If at any time there are questions regarding the proper use of this analyzer, please contact

us at 513-772-0060 for assistance.

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Super Systems Inc.

USA Office

Corporate Headquarters:

7205 Edington Drive

Shipping Address:

7245 Edington Drive

Cincinnati, OH 45249

Phone: [phone]

http://www.supersystems.com

Super Systems Europe

Unit E, Tyburn Trading Estate,

Ashold Farm Road, Birmingham

B24 9QG

UNITED KINGDOM

Phone: [phone]

http://www.supersystemseurope.com

Super Systems México

Sistemas Superiores Integrales S de RL de CV

Acceso IV No. 31 Int. H Parque Industrial

Benito Juarez

C.P. 76120 Queretaro, Qro.

Phone: [phone]

http://www.supersystems.com.mx

Super Systems China

No. 369 XianXia Road

Room 703

Shanghai, CHINA

200336

Phone: [phone]

http://www.supersystems.cn

Super Systems India Pvt. Ltd.

A-26 Mezzanine Floor, FIEE Complex,

Okhla Indl. Area, Phase – 2

New Delhi, India 110 020

Phone: [phone]

http://www.supersystemsindia.com

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Table of Contents

Introduction ................................................................................................................................................... 4

Specifications ................................................................................................................................................ 4

Electrical Connections / Terminal Assignments ........................................................................................... 4

Getting Started .............................................................................................................................................. 5

Default Settings ............................................................................................................................................. 5

Modifying the Default Settings ...................................................................................................................... 5

Description of Menu Items ............................................................................................................................ 5

Exit Program ................................................................................................................................................... 5

Instrument Information .................................................................................................................................. 5

Communication Setup ..................................................................................................................................... 5

Instrument Configuration ............................................................................................................................... 5

Percent Hydrogen ....................................................................................................................................... 6

Percent Dissociation................................................................................................................................... 6

Percent Ammonia ....................................................................................................................................... 6

Minimum H2 for NH3 Display Parameter .............................................................................................. 6

Nitriding Potential ...................................................................................................................................... 6

Output Configuration ....................................................................................................................................... 6

Output Calibration ........................................................................................................................................... 6

Sensor Calibration .......................................................................................................................................... 7

Performing a Zero Calibration ................................................................................................................... 7

Performing a Span Calibration .................................................................................................................. 7

Trend Chart...................................................................................................................................................... 8

Chart Sub Menu ............................................................................................................................................. 10

Control Interface Options ............................................................................................................................ 11

Parts List and Internal Components ........................................................................................................... 11

Warranty ...................................................................................................................................................... 13

Revision History .......................................................................................................................................... 14

Appendix A: Drawings (Electrical, Plumbing, and Mounting) ...................................................................... 15

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Introduction

This instrument uses the measurement of Hydrogen to display % Hydrogen (H2), % Dissociation (DA), and
% Ammonia (NH3). When the flow rates of Nitrogen, Ammonia, and Dissociated Ammonia are manually
entered, the instrument can also calculate Nitriding Potential (KN).

It is suggested that this device should be calibrated on a routine basis, such as once per year or as
prescribed by the user’s quality system requirements.

Specifications

 Power Requirements: 100-240 VAC
 Current Draw: Max. 0.2 Amps
 Sensor Technology: Thermal Conductivity
 User Interface: 3.5” Color QVGA TFT LCD Touch Screen
 Measurement Range: 0-100% H

2

 Hydrogen Measurement Accuracy: +/- 1%
 Hydrogen Measurement Repeatability: +/- 1%
 Hydrogen Measurement Resolution: 0.01%
 Analog Outputs: Two Isolated 4-20mA (User Configurable)
 Analog Output Resolution: 0.005mA
 Analog Output Accuracy: +/- 0.01% of Range
 Analog Output Linearity: +/- 0.01%
 Analog Output Load Resistance: Minimum 0 Ohm, Maximum 500 Ohm
 Digital Communications: RS485 Modbus, Ethernet
 Enclosure Size (Without Filter): Approx. 13”L x 13”W x 6”D / 330mmL x 330mmW x 142mmD
 Enclosure Weight: 22.5 lbs. / 10.2 kg.
 Enclosure Ventilation: Continuous Purge Fan, Dual Vents
 Recommended Flow Rate: 1.5 to 2.0 SCFH / 0.71 to 0.94 lpm
 Process Gas Fittings: Stainless Steel Compression for ¼” OD Tubing
 Calibration Gas Fitting: 1/8” Barb (can be removed for 1/8” Female NPT Port)
 Operating Environment: 10-90 %RH (Non-Condensing)
 Operating Temperature: 32 to 122°F / 0 to 50°C
 Sample Gas Temperature: 32 to 158°F / 0 to 70°C

Electrical Connections / Terminal Assignments

Wire Number

Function

1000

AC Line Power (100-240VAC)

1002

AC Neutral Power

Ground

AC Ground

1121

Analog Output Common (+)

1111

Analog Output #1 (-)

1121

Analog Output Common (+)

1131

Analog Output #2 (-)

1081

RS485 (-)

1091

RS485 (+)

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Getting Started

Please refer to the enclosed drawing for instructions regarding the proper electrical and mechanical
installation of this instrument. The flow meter on the door of the enclosure should be adjusted to
maintain 1.5 SCFH of process gas flow.

Default Settings

When the instrument is turned on, it will display % H2 on the screen. To display additional values (% DA,
% NH3, or KN), see the “Instrument Setup” screen. The first 4-20mA output will be set up to retransmit
the %H2 value scaled for 0 to 100%, and the second output will be set up for %DA also scaled for 0-100%.
Any changes to these default parameters will be stored so they will not need to be re-entered when the
power is shut off to the instrument

Modifying the Default Settings

To access the operational and setup parameters, press the “menu” button at the lower left section of the

screen. This will allow you to select only two options, Exit Program and Instrument Information. To
prevent unwanted modification to the operation of the instrument, these are the only options available

unless the user logs in. To access the other menu options, press the “Login” button and enter “2”. This

will give the operator access to the setup and operational parameters.

Each individual menu option is described in detail below:

Description of Menu Items

Exit Program

The touch screen display is constantly writing data to its flash card for storage, and it is important that
the instrument not be shut down during this process. Before removing power from the enclosure, select

“Exit Program”. It will ask is you are sure that you want to shut down the interface. By answering yes, it

closes the operating program in an orderly manner. Once the standard Microsoft Windows screen
appears it is safe to remove power from the instrument. If this procedure is not followed, there is a
chance that there could be an error writing to the flash card that could cause problems with the operation
of the instrument.

Instrument Information

This screen provides information on any applicable revision levels and serial numbers. It also shows if
the instrument is logging data. There are no functions that can be performed on this screen; it is for
informational purposes only.

Communication Setup

The communication methods shown on this screen are for display only and cannot be modified. The baud
rates can be adjusted but they have been optimized for this instrument and modification is not
recommended.

Instrument Configuration

This instrument is capable of displaying four different parameters. These include:

 Percent Hydrogen (H

2

)

 Percent Dissociation (DA)
 Percent Ammonia (NH

3

)

 Nitriding Potential (K

N

)

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The Percent Hydrogen is displayed on the main screen at all times. One additional parameter can be

displayed along with Hydrogen by highlighting it and pressing the “OK” button. A clearer description of
each of these parameters can be found in Appendix “A”, Gas Nitriding Technical paper.

Percent Hydrogen

The percent hydrogen is the amount of Hydrogen that is being detected by the thermal conductivity
sensor inside the instrument. There are no additional calculations being performed to this value.

Percent Dissociation

Dissociation is derived from the amount of Hydrogen in the sample gas.

Percent Ammonia

The amount of Ammonia can also be inferred from the Hydrogen value.

Minimum H2 for NH3 Display Parameter

This analyzer measures %H2 (in ppm) and calculates a gas composition of DA or NH3 (with %DA + %NH3
= 100%). An available analog output provides a 4-20mA signal representing either DA or NH3--defaulting
to 4mA when zero hydrogen is measured.

Due to the high accuracy of the sensor, trace amounts of Hydrogen may be measured in "near zero"
environments, resulting in oscillations between 4- and 20mA when configured for %NH3. To prevent such
oscillations the user may define a Minimum H2 to fix the output at 4mA until the measured Hydrogen
percentage exceeds such a threshold.

Nitriding Potential

The accurate calculation of Nitriding Potential (KN) requires the flow rates of other gases that are being
introduced into the process. These flow rates are measured in SCFH (Standard Cubic Feet per Hour). KN
can only be calculated by entering the flow of Nitrogen (N2), Ammonia (NH3) and % Dissociated Ammonia
(%DA). These values are entered at the bottom of the main screen when KN is selected.

Output Configuration

There are two 4-20mA outputs that can be configured for any of the four parameters. For each input, the
operator can select the Source (H2, DA, NH3, KN), the zero value (the value to be represented by 4mA) and
the span value (the value to be represented by 20mA).

 Output 1 can be measured from Terminal #1121(+) and 1111 (-).
 Output 2 can be measured from Terminal #1121(+) and 1131 (-).

Output Calibration

Accurate retransmission of the selected parameters can only be obtained through calibrating both of the
analog outputs. This is done at the factory prior to shipment, however it is a relatively simple procedure
that can be performed in the field if desired. To perform a calibration, a multimeter with a current input
is required. Please keep in mind that the accuracy of the instrument used to calibrate the outputs is
directly related to the accuracy of the outputs after calibration, so a meter calibrated against NIST
(National Institute of Standards and Technology) standards is preferred. Before performing any
calibrations, all other devices must be disconnected from the analog outputs. Multiple devices on the
outputs will cause inaccurate measurement of current.

Attach the leads of the multimeter to the terminals for Output 1. The positive lead should be attached to
Terminal #1121 and the negative lead to Terminal 1111. Select “Zero Output 1” and press the “Prep for
Cal” button. The low limit of the output is 4mA, so 4.000 is shown as the default measured value. Ideally
the meter connected to the outputs will also show 4.000. If the two values are not close enough to obtain
the desired level of accuracy, a calibration should be performed.

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If, for example, the meter connected to the outputs reads 4.216mA, then the value “4.216” should be
entered on the screen as the Measured Value. Once the value has been entered, press the “calibrate”

button. This will offset the mA output of the instrument in an amount that results in an exact output of

4.000mA. When the calibration is complete, the multimeter should be reading 4.000mA (+/- .005).

The procedure can be repeated for the Span of Output 1. When “Span Output 1” is selected and “Prep for
Cal” is pressed, the instrument will output the high output limit, which is 20mA. The multimeter will

display the actual output from the instrument, and if it is not within the desired tolerance it can be
calibrated using the same procedure as above.

To calibrate Output 2, attach the leads of the multimeter to Terminal #1121 (+) and the negative lead to
Terminal 1131 (-) and follow the same procedure that was used for the first output.

Sensor Calibration

It is suggested that this device should be calibrated on a routine basis, such as once per year or as
prescribed by the user’s quality system requirements.

A proper calibration of the sensor requires two gases. The first gas should be pure Nitrogen or Argon.
This contains no Hydrogen, and is therefore referred to as the Zero Gas. The second gas is the Span Gas.
The Span Gas should ideally contain a quantity of Hydrogen similar to the amount of Hydrogen in the
process gas. The Span Gas should also include any other gases that are present in the process gas in
their respective percentages. The more similar to the process gas the calibration gas is, the more
accurate the calibration will be.

Performing a Zero Calibration

On the Sensor Calibration page, select “Zero Hydrogen”. Turn the valve on the side of the enclosure to
the “Calibration Gas” position, and attach the Zero gas to the “Calibration Gas Inlet” port. Begin the flow

of gas at a rate of 1.5 to 2.0 SCFH as measured on the flow meter on the door of the enclosure. The gas
should not be under any pressure other than the amount required to maintain the appropriate flow
amount. The target Value is shown on the screen. For a Zero Calibration, this will be 0.00 (the amount of
Hydrogen in the Zero Gas). The Measured H2 Value can be seen at the bottom of the screen. When this
value comes to equilibrium, it will not be showing any upward or downward trends, only the slight
oscillation of the readings. This usually occurs in approximately 30 seconds. When the sensor is at

equilibrium, press the green “Calibrate” button to perform the zero calibration. After the Zero

Calibration is complete, turn off the flow of gas and disconnect it from the enclosure.

Performing a Span Calibration

To perform a span calibration, select “Span Hydrogen”, attach the Span Gas to the Calibration Gas Inlet
port, and begin the flow of gas at 1.5 to 2.0 SCFH. The Target Value should be set to the exact amount of
Hydrogen that is in the Span Gas cylinder. Then the same procedure should be followed as the Zero
calibration, with the “Calibrate” button being pressed after the readings reach equilibrium. After the
Span Gas calibration is complete, turn off the flow of gas, disconnect the cylinder from the enclosure, and
restore the valve on the side of the instrument to the “Sample Gas” position. This will re-connect the
sensor to the process gas stream.

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Trend Chart

The Trend Chart Display shows between 1 hour and 24 hours of process variable data on the screen and
can be scrolled back to view all of the data stored on the hard drive. The vertical timelines change as the
time changes on the screen.

The function buttons run along the bottom of the screen.

The folder button - - stores saved templates. A different chart template can be selected here.

The Trend Lines button - - will allow the user to select or de-select the trend lines on the trend
chart to display. If the checkbox next to each trend line is checked, then that trend line will be displayed.

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The Datagrid View button - - will display a screen with the trend data in a grid format instead of
with trend lines. The trend data is shown in 1-minute intervals. Clicking on the OK button on this screen
will close the screen down and return to the Chart Display screen.

The Refresh button - - will refresh the screen’s trend data if the screen is not in real-time mode.

The left-pointing green arrow button - - will move the chart’s view backward in time by the
specified chart interval.

The chart interval button - - will determine the number of hours displayed on the trend chart. The
options are: 1 Hour, 2 Hours, 4 Hours, 8 Hours, 12 Hours, or 24 Hours.

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The right-pointing green arrow button - - will move the chart’s view forward in time by the
specified chart interval.

The Play/Pause button - - will put the chart into real-time mode if it is not in real-time mode, or
take the chart out of real-time mode if it is. When in real-time mode, the chart will automatically be
updated once a minute.

Chart Sub Menu

There is a sub-menu available by putting a finger or a stylus anywhere on the chart and holding it there
for two seconds.

The sub-menu will have the following options available: Zoom, Restore, Add Note, Data,
and Exit.

The Zoom option will allow the user to zoom in on a particular part of the screen. Once
this has been selected, the user can take a stylus or a finger and create a box around
the desired data. Once the user releases the stylus or finger, a zoom is no longer
possible, and the user will need to re-select the option from the sub-menu to zoom in

again.

The Restore option will back out of any zoom options that have been performed and display the chart
screen as it initially was.

The Add Note option allows the operator to enter a note on the chart, similar to writing on a paper chart.
The note shows up when the chart is printed out using the utility software included with the SGA
instrumentation. Pressing the Add Note option displays a screen where the operator can enter the
operator ID or initials and a note. The user has the option to enter a note using the operator interface
keyboard, where he or she will be able to type in the note; or the user can use the Signature mode, which
will allow them to write a note using a stylus.

The Data option will show the trend data as a data grid instead of the trend lines on a chart. This

functionality is exactly the same as if the user pressed the Datagrid View button - - from the chart
screen.

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Exit will close out the sub-menu without selecting an item.

Pressing the red ‘X’ in the top right-hand corner of the screen will take the user back to the status
screen.

Control Interface Options

Also available is SSi’s TS Manager. TS Manager is a utility program that can be loaded onto any

Windows® based computer (operating Windows XP® or higher). This software will allow the computer to
read the data from the TS Flashcard, and allow it to be viewed in a manner that is similar to a strip chart
recorder. The screen will need to be connected to the local network (using a static IP address) for
communications capabilities. The TS Manager manual can be obtained from the SSi website.

Parts List and Internal Components

The following items can be purchased as needed for the Hydrogen Nitrider Analyzer.

Part Number

Description

31604

2 GB SD card

37026

Fan (24VDC, 60mm)

37029

Fan filter assembly

37150

3-way ball valve

37050

High capacity bowl filter

37051

High capacity filter element

34444

Tubing

33097

Circuit breaker

31135

Power supply

A20624

Hydrogen sensor

31296

3.5” touch screen

Full Unit

13537

Hydrogen Nitrider Analyzer

The following diagram illustrates the location of important internal components of the Hydrogen Nitrider
Analyzer, along with relevant part numbers.

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3.5” touch screen*
(PN 31296)

Tubing
(PN 34444)

Fan**

(PN 37026)

Circuit breaker

(PN 33097)

Power supply
(PN 31135)

High capacity
bowl filter
(PN 37050)

High capacity
filter element
(PN 37051)

Hydrogen sensor
(PN A20624)

3-way ball valve
(PN 37150)

*SD card is contained within touch screen.

SSi part number for 2 GB SD card is 31604.

**Fan filter assembly (PN 37029) is contained
within fan housing.

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Warranty

Limited Warranty for Super Systems Products:

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

The limited warranty does not cover damage resulting from commercial use, misuse, accident,
modification or alteration to hardware or software, tampering, unsuitable physical or operating
environment beyond product specifications, improper maintenance, or failure caused by a product for
which SSI is not responsible. There is no warranty of uninterrupted or error-free operation. There is no
warranty for loss of data—you must regularly back up the data stored on your product to a separate
storage product. There is no warranty for product with removed or altered identification labels. SSI DOES
NOT PROVIDE ANY OTHER WARRANTIES OF ANY KIND, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED
WARRANTIES OR CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
SOME JURISDICTIONS DO NOT ALLOW THE LIMITATION OF IMPLIED WARRANTIES, SO THIS LIMITATION
MAY NOT APPLY TO YOU. SSI is not responsible for returning to you product which is not covered by this
limited warranty.

If you are having trouble with a product, before seeking limited warranty service, first follow the
troubleshooting procedures that SSI or your authorized SSI dealer provides.

SSI will replace the PRODUCT with a functionally equivalent replacement product, transportation prepaid
after PRODUCT has been returned to SSI for testing and evaluation. SSI may replace your product with a
product that was previously used, repaired and tested to meet SSI specifications. You receive title to the
replaced product at delivery to carrier at SSI shipping point. You are responsible for importation of the
replaced product, if applicable. SSI will not return the original product to you; therefore, you are
responsible for moving data to another media before returning to SSI, if applicable. Data Recovery is not
covered under this warranty and is not part of the warranty returns process. SSI warrants that the
replaced products are covered for the remainder of the original product warranty or 90 days, whichever is
greater.

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Revision History

Rev.

Description

Date

MCO#

NEW

First release

N/A

A

Revised terminal numbers; added product diagrams;
added part numbers; updated format of document.

11/7/2014

2155

B

Revised specifications for hydrogen measurement.

9/23/2015

2168

C

Added minimum H2 option for NH3 Display option

6/5/2019

2267

D

Added trend chart and TS Manager info

4/30/2020

2290

E

Added calibration interval text

3/25/2021

2308

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Appendix A: Drawings (Electrical, Plumbing, and Mounting)

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