Super Systems PGA3500 User Manual
Operations Manual
PGA 3500
Portable 3-Gas IR Analyzer
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 (800) 666-4330 for assistance.
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060 800-666-4330
Fax: 513-772-9466
www.supersystems.com
SSi Manual 4559 Page 1 of 26 3-Gas Analyzer PGA3500
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Table of Contents ............................................................................................................. 2
WARNINGS ...................................................................................................................... 3
Typical Diagnostic Uses of the PGA3500 ..................................................................... 4
PGA 3500 Operating Instructions ................................................................................ 5
Introduction ............................................................................................................... 5
Specifications ............................................................................................................. 5
Basic Operating Description ......................................................................................... 6
Keypad Assignments ................................................................................................... 6
Analyzer Start-Up Procedure ........................................................................................ 6
Sampling Criteria ........................................................................................................ 6
Filters ........................................................................................................................ 7
Condensation / Moisture ............................................................................................. 7
Battery ....................................................................................................................... 7
Menu List ................................................................................................................... 8
Note about Menu Numbers .......................................................................................... 9
IR Status Display – Menu Page 1 ......................................................................... 10
IR Overall Status Display – Menu Page 2 ............................................................ 10
Combustion Display – Menu Page 3 .................................................................... 12
Pump Control - Menu Page 4 ............................................................................... 12
Set Display Values – Menu Page 5 ....................................................................... 12
Help Page - Menu Page 6 ..................................................................................... 13
Calibration Dates and Run Times - Menu Page 7 ................................................ 13
Language / Lengua – Menu Page 8 ..................................................................... 13
Battery Status – Menu Page 9 ............................................................................. 14
About/Sign-On – Menu Page 10 .......................................................................... 14
Revision Display – Menu Page 11 ........................................................................ 15
Logged Data Start Date – Menu Page 12 ............................................................. 15
Logged Data File – Menu Page 13 ....................................................................... 15
Session - Menu Page 14 ....................................................................................... 16
Sampling Parameters - Menu Page 15 ................................................................ 17
Set The Date and Time - Menu Page 16 ............................................................... 19
Port Setup - Menu Page 17 .................................................................................. 19
Zero Calibration – Menu Page 18 ......................................................................... 20
O2 Cell Calibration – Menu Page 19 .................................................................... 20
Communications Setup – Menu Page 20 ............................................................. 21
Calibrate Flow Meter – Menu Page 22 ................................................................. 22
Calculation Factors - Menu Page 23 .................................................................... 22
Span Calibration – Menu Page 24 ........................................................................ 23
Set Pass Codes - Menu Page 25 ........................................................................... 23
Set IP Address- Menu Page 26 ............................................................................ 24
General Information - Menu Page 28 .................................................................. 24
PGA3500 Spare Parts .................................................................................................. 25
Revision History ........................................................................................................... 26
SSi Manual 4559 Page 2 of 26 3-Gas Analyzer PGA3500
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WWAARRNNIINNGGSS
Shipping the instrument back to Super Systems
When returning the PGA3500 to SSI for calibration or any other service, it must be properly
protected during shipment. The best method of packaging the instrument is in its original
packaging which includes custom-fit foam. For this reason, the original packaging should
be retained. If the original packaging is not available, the instrument should be shipped in
a suitably sized cardboard box with at least 4” of solid padding on each side of the instrument
(not packing peanuts).
In the event that the PGA3500 is returned to Super Systems with improper packaging, we
reserve the right to charge for replacement custom foam and a new box instead of
risking damage to the instrument during reshipment.
Super Systems will not be responsible for damage caused by improper packaging.
RETAIN ORIGINAL PACKAGING.
PROPER PACKAGING IS REQUIRED WHEN
RETURNING PGA FOR CALIBRATION OR REPAIR.
DAMAGE CAUSED BY IMPROPER
PACKAGING IS NOT COVERED UNDER THE WARRANTY.
IT IS THE RESPONSIBILITY OF THE OPERATOR TO ENSURE THAT THE
GAS BEING SAMPLED DOES NOT PRODUCE ANY CONDENSATION.
SENSOR DAMAGE DUE TO MOISTURE WILL VOID THE WARRANTY
Moisture and Condensation
Depending on the composition of the gas being sampled, it is possible that condensation
could occur in the sample tubing. This is not likely in a properly operating endothermic
atmosphere, however condensation can occur in either a poorly operating endothermic or any
exothermic atmosphere. Do not leave the PGA3500 unattended for long periods of time
unless you are confident that the gas being sampled will not condense in the sample lines. If
moisture gets inside the instrument it will result in permanent damage the sensors, which is
not covered under the warranty.
SSi Manual 4559 Page 3 of 26 3-Gas Analyzer PGA3500
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The PGA3500 Analyzer measures CO, CO2, and CH4. Carbon potential can be calculated using
furnace temperature and the relationship of these 3-gases. Oxygen probe real-time
measurement of the furnace atmosphere can be verified by 3-Gas analysis. In addition to
being an excellent diagnostic device, the PGA3500 will provide the necessary data to finetune your atmosphere control.
Endothermic Generator Diagnostics
The effectiveness of the catalyst is measured by the CH
content. Less than 0.5% is an
4
indication of properly functioning catalyst. Higher concentrations indicate the necessity for
either conditioning or replacement.
Measuring the level of CO in the carrier gas allows correction of the % carbon reading at the
furnace.
Heat Treat Furnaces – Conventional Endo Gas
Furnace atmosphere carbon potential (% C) can be verified with the PGA3500.
Measuring carbon monoxide (CO) and carbon dioxide (CO
) can show possible problems (i.e.
2
water leaks, air leaks, and radiant tube leaks).
The PGA3500 measures the free methane (CH
) in the furnace atmosphere.
4
Heat Treat Furnaces – Nitrogen/Methanol Endo Gas
The carbon monoxide (CO) level in the furnace atmosphere indicates the effectiveness of the
cracking of the methanol. Equilibrium of the methanol cracking reaction (CH
OH Æ CO + 2H2)
3
is temperature dependent.
Heat Treat – Oxygen Sensor Control
Periodic verification of the performance of oxygen probes.
COF and PFC adjustments can be made (based on the calculations of the 3 gases) to provide
more precise control of the carbon in the furnace atmosphere.
Combustion – Burner Balancing
Measures excess O
in the flue gas to allow burner adjustments.
2
SSi Manual 4559 Page 4 of 26 3-Gas Analyzer PGA3500
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Introduction
The Model PGA3500 is a portable 3-Gas IR analyzer with an Oxygen (O2) cell on-board. It
measures Carbon Monoxide (CO), Carbon Dioxide (CO
) and Natural Gas (CH4) typically found
2
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: 0.1 to 25.0%
O
2
* Note: The CO and CH4 sensors have been calibrated to be most accurate within the ranges
as shown above, however both sensors are capable of measuring gas concentrations of up to
100.00%.
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
AC Power: 90 to 230 VAC, 50 to 60 Hz, 60 Watts
DC Power: 12VDC rechargeable NiCd battery
(Charger integrated inside instrument)
Communications: RS232, Ethernet, RS485 (Future Use)
Data Storage: Continuous automatic data logging
Data Retrieval: Visible in graphical and tabular format using
XGA Viewer software (included)
Operating Temperature: 32° to 122° F (0° to 50° C)
Dimensions: Approx. 16”H X 20”L X 8”D
Weight: Approx. 30 lbs.
SSi Manual 4559 Page 5 of 26 3-Gas Analyzer PGA3500
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Basic Operating Description
The Model PGA 3500 has been designed for the simultaneous analysis of CO, CO2 and CH4 in
heat-treat furnace atmosphere gases. It has a 16 line by 40-character 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.
Keypad Assignments
All of the functions of the PGA3500 are controlled from the keypad. The functions of each
button are as follows:
0 – 9 are used to enter numeric data that
can vary with each page.
“.” is used to enter a decimal point where
necessary for data entry.
Enter is used when entering numeric data
from the keypad or initiating automatic
functions.
Ï and Ð are used to navigate through the
menu options or scroll through data on a
specific page.
Esc is the escape key. This clears any entered text, and if continuously pressed toggles
between the main page and the menu list.
On most pages, this key can be used to turn the pump on and off (without using Screen
4). On some screens it is used to change a selection or view additional data.
123
456
789
ESC.
0
z
Ï
ENTER
Ð
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 three minutes.
During this time, the user will be prevented from accessing the calibration screens since the
sensors have not had enough time to provide accurate data. It is recommended that the
instrument is powered on for four or five minutes prior to use, although measurements can
be taken within only three.
Sampling Criteria
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 infrared gas
detection requires that a clean, soot free sample be available for analysis. This will also
increase the life of the filter elements, and reduce the possibility that soot will enter the unit
and contaminate the sensors.
SSi Manual 4559 Page 6 of 26 3-Gas Analyzer PGA3500
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On a furnace, the ideal port would be found on SSi’s Sample Port (Part Number 20263). If
this were 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 on the PGA3500 to the
sample port.
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 by pressing the circular arrow key, 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 a light-blue colored 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 a yellow/white color. 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. If the primary filter is properly maintained, the secondary
filter will rarely require changing.
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 the 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 continuing before operation is resumed.
Battery
The battery in the PGA3500 is intended to provide more than enough power to operate the
unit continuously for an eight-hour shift. When
the unit is in need of a charge. To charge the PGA3500, plug it into a 110 or 220VAC power
source using the supplied power cord. The LED above the power cord input will appear 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
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.
Battery Low
is displayed on the LCD screen,
Battery Low
SSi Manual 4559 Page 7 of 26 3-Gas Analyzer PGA3500
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It is possible to view the condition of the battery by accessing Menu page #9 -
.
Status
Battery
Menu List
The menu list shows the available pages displayed six at a time. To access the list, press the
Esc key. Depending upon where you are starting from, it may require pressing this button
more than once. The up (Ï) and down (Ð) arrows are used to scroll through the selections,
which are repeated below. To go to a specific page, either type in the page number and
press Enter, or use the arrow keys to highlight your selection and then press Enter.
Operator Level – No Pass Code Required
1. IR STATUS DISPLAY
2. IR OVERALL STATUS DISPLAY
3. O2 DISPLAY
4. PUMP CONTROL
5. SET DISPLAY VALUES
6. HELP
7. CALIBRATION DATES
8. LANGUAGE / LENGUA
9. BATTERY STATUS
10. ABOUT / SIGN-ON
11. REVISION DISPLAY
12. LOGGED DATA START DATE
13. LOGGED DATA DISPLAY
14. SESSION
15. SAMPLING PARAMETERS
Supervisor Level – Level 1 Pass Code Required
16. SET THE DATE AND TIME
17. PORT SETUP
18. ZERO CALIBRATION
19. O2 CELL CALIBRATION
20. COMMUNICATIONS SETUP
Configuration Level – Level 2 Pass Code Required
22. CALIBRATE FLOW METER
23. CALCULATION FACTORS
24. SPAN CALIBRATION
25. SET PASS CODES
26. SET IP ADDRESS
27. OPTIONAL CELL CALIBRATE
28. GENERAL INFORMATION
Page 21 is reserved for future use and does not exist at this time. To minimize the possibility
of unintended modifications to the instrument, certain menu pages will require the entry of a
pass code to access them. Pages 1 through 15 are Operator level screens that do not require
any security codes. Pages 16 - 20 are Supervisor screens requiring a level 1 pass code
SSi Manual 4559 Page 8 of 26 3-Gas Analyzer PGA3500
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