Super Systems PGA3000 User Manual
Operations Manual
PGA 3000
Portable 3-Gas IR Analyzer
Please read, understand, and follow these instructions before operating thi s 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 (800) 666-4330 for assistance.
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060 800-666-4330
Fax: 513-772-9466
www.supersystems.com
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Table of Contents
PGA 3000 Operating Instructions...................................................................................................... 3
Introduction........................................................................................................................................... 3
Specifications........................................................................................................................................ 3
Basic Operating Theory ..................................................................................................................... 4
Analyzer Start-Up Procedure........................................................................................................... 4
Filters ....................................................................................................................................................... 5
Condensation / Moisture .................................................................................................................. 5
Battery..................................................................................................................................................... 5
Menu List................................................................................................................................................. 6
IR Status Display – Menu Page 1................................................................................................... 7
IR Overall Status Display – Menu Page 2 ................................................................................... 7
Combustion Display – Menu Page 3.............................................................................................. 8
Pump Control - Menu Page 4........................................................................................................... 8
Set Display Values – Menu Page 5................................................................................................. 8
Help Page - Menu Page 6.................................................................................................................. 9
Calibration Dates and Run Times - Menu Page 7..................................................................... 9
About/Sign-On – Menu Page 11................................................................................................... 10
Start logger – Menu Page 12......................................................................................................... 10
Logged Data File – Menu Page 13 ............................................................................................... 11
Zero Calibration – Menu Page 14................................................................................................. 11
O2 Cell Calibration – Menu Page 15............................................................................................ 12
Port Setup - Menu Page 21 ............................................................................................................ 12
Set The Date and Time - Menu Page 22..................................................................................... 12
Data Set Page - Menu Page 23 ..................................................................................................... 12
Span Calibration – Menu Page 24................................................................................................ 13
Set Pass Codes - Menu Page 25.................................................................................................... 13
Clear Logged File - Menu Page 26............................................................................................... 13
Typical diagnostic uses: .................................................................................................................. 14
Spare Parts........................................................................................................................................... 15
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PGA 3000 Operating Instructions
Introduction
The Model PGA3000 is a portable 3-Gas IR analyzer with an Oxygen (O2) cell onboard. It measures Carbon Monoxide (CO), Carbon Dioxide (CO2) and Natural
Gas (CH4) typically found in an endothermic atmosphere.
Specifications
The unit is designed and manufactured for the atmosphere heat-treating
industry.
CO range: 0.00 to 30.00 %
range: 0.000 to 2.000 %
CO
2
range: 0.00 to 15.00 %
CH
4
range: 0.01 to 25.00%.
O
2
Sampling method: Extraction by internal pump (when necessary)
Accuracy and repeatability: ± 1% of full scale
Flow Meter: Inside case lid and also on-screen
Pump Operation: On/Off/Automatic
Power: 115/230 VAC - 50/60 Hz – 60 Watts
(Rechargeable Battery Power)
Data Retrieval: Up to 4 gases - 10 Furnaces/Generators
500 minutes/furnace
Data collection review on PGA3000 screen or
Upload to Microsoft EXCEL
Operating Temperature: 32° to 122° F (0° to 50° C)
Dimensions: Approx. 16”H X 20”L X 8”D
Weight: Approx. 30 lbs.
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Basic Operating Theory
The Model PGA 3000 has been designed for the simultaneous analysis of CO,
CO2 and CH4 in heat-treat furnace atmosphere gases. It has a 16 line by 40character LCD display and a 4 x 4 keypad for the operator interface. Information
is presented to the operator on various screens. The operator selects the
appropriate page and enters the number using the keypad.
Numeric keypad key assignments.
0 – 9 are used to enter numeric data.
* is the escape key and clears all numbers previously entered.
# will display a specific menu, to select a specific page, press a numeric key (or
two numeric keys) and then the # key.
A is used as the ENTER key.
B moves the cursor up.
C moves the cursor down.
D adds a decimal point to the data being entered on a screen, also toggles from
one furnace to the next on the data collection page.
Analyzer Start-Up Procedure
Turn the power switch on and allow the instrument to warm up until numbers
appear on the default screen instead of ********. This process should take
approximately two minutes.
Accurate readings are only possible if the sample is taken from a clean (free of
excess carbon buildup) sample port. The current state-of-the-art technology
associated with IR sampling requires that a clean, soot free sample be available
for analysis. A clean sample port will also increase the life of the filter elements,
and reduce the possibility that soot will enter the unit and contaminate the
sensors.
On a furnace, the ideal port would be found on SSi’s Sample Port (Part Number
20263). If this is not available, the burnout port of a freshly burned-out Gold
Probe™ would be an alternative, although this would still contain a trace amount
of soot.
On a generator, a dedicated sample port should be available. This sample port
should be blown out before it is used, which will remove any soot that has
accumulated in the line. This is accomplished by opening the valve without
connecting the analyzer. Wait until the gas stream is clean before proceeding
and connect the sample line to the sample port.
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The ideal flow rate for sampling should be between 1.0 and 1.5 Standard Cubic
Feet per Hour (SCFH). A visual indication of flow rate can be obtained through
the mini flow meter located on the inside of the lid of the case, or by the digital
flow meter on the left side of the display. The flow meter on the inside of the
case also contains a dial that allows the user to restrict the flow if necessary to
maintain an appropriate flow rate. If the sample gas is not under pressure, the
internal pump can be used to extract it. The internal pump can be operated
manually, or it can be turned on or off automatically when it detects low sample
flow.
Filters
There are two filters that are intended to prevent soot or other contaminants
from entering the unit. The first is an in-line filter that is located at the end of
the sample tubing assembly. The second is a bowl filter located on the inside of
the lid. Periodic inspection of these filters will ensure smooth operation. When
new, the elements in both of these filters are white. Both are oriented in the
sample stream in a manner that causes any contaminants to collect on the
outside of the filter media, which allows for a visual inspection of filter status.
Condensation / Moisture
When a hot gas is cooled rapidly, moisture in the gas can condense and form
water. This water can collect in the sample tubing assembly, and eventually
enter the bowl filter. Care must be taken to ensure that no water enters the
unit, as this will cause permanent damage to the sensors. The unit should be
closely monitored during operation to determine if moisture is collecting in the
bowl filter. If this is the case, the bowl filter basin can be removed and emptied
by unscrewing it. Although water in the bowl filter will not cause damage to th e
unit, this filter is not intended to be used as a condensation receptacle. If
moisture has collected in the bowl filter, sampling should be stopped, and steps
should be taken to prevent this from occurring before operation is resumed.
Battery
The battery in the PGA3000 in intended to provide more than enough power to
operate the unit continuously for an eight-hour shift. When
Battery Low
is
displayed on the LCD screen, the unit is in need of a charge. To charge the
PGA3000, plug it into a 110 or 220VAC power source using the supplied power
cord. The LED above the power cord input is red while the unit is being charged,
and it will turn to green when charging is complete.
For maximum battery life, do not recharge the battery after each use unless the
Battery Low
message appears on the screen. Reducing the number of times that
the unit is charged will maintain the battery’s original storage capacity for a
longer period of time.
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