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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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.
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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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(default = 1). Pages 22 – 26 are Configuration screens requiring a Level 2 pass code (default
= 2).
At the bottom of the Menu Screen is a status bar. This tells the current date and time, and
also displays the internal temperature (IT) of the instrument. This internal temperature
should never exceed 50
Note about Menu Numbers
Each menu screen has a unique number that will be displayed in the upper left-hand corner
of the screen. This number is shown for reference. If you know the menu number of the
screen that you would like to go to, this number can be typed in to access it directly from the
IR Status Display or the Menu List.
SSi Manual 4559 Page 9 of 26 3-Gas Analyzer PGA3500
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IR Status Display – Menu Page 1
The IR status display shows the current
readings of CO, CO2 and CH4. Also shown
is the relative flow rate of the sample by a
fuel gauge on the left-hand side of the
screen. The sample pump may be turned
on or off by pressing the circular arrow key
at the lower right-hand side of the keypad.
IR Overall Status Display – Menu Page 2
The IR Overall Status Display provides the
user with the calculated carbon percentage
(%C) from two different sources (probe and
infrared). It provides information to allow the
atmosphere controller to be “tuned” to match
the information from the 3-gas analyzer.
To obtain the most information from this
screen, some data must be manually entered.
This is done at the right hand side of the
screen under the heading
keypad to enter numbers, and the arrow keys
to move the highlighted area up and down, the following data should be entered:
FC TC= This is the furnace thermocouple value, or the furnace temperature.
PB MV= This is the millivoltage from the carbon probe.
PB TC= This is the probe thermocouple value, or the probe temperature.
COF= This is the CO Factor value read from the SSi, Honeywell, Barber Colman, Yokogawa,
or other atmosphere controller.
PF= This is the Process Factor value read from the Marathon Sensors atmosphere controller.
Temperature Units = This determines the measurement units for temperature. Enter 0 for
Fahrenheit or 1 for Celsius.
Measurement of Infrared % Carbon (IR %C)
To accurately measure the % carbon in a furnace atmosphere, the instrument will need to
know the values of each of the three gases and the temperature of the gas being measured.
At the left side of the screen, under the heading
CO2, and CH4. The values of these three gases, plus the furnace temperature (FC TC) value,
will result in the calculation of the IR % Carbon (IR %C). This is displayed in the center of
the screen, under the heading
Calculated
Measured
. Please note that if the furnace temperature
, are the real-time values of CO,
Operator
. Using the
SSi Manual 4559 Page 10 of 26 3-Gas Analyzer PGA3500
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information has not been entered correctly the resulting carbon calculation will NOT be
accurate.
Measurement of Probe % Carbon (PB %C)
The measurement of the probe % carbon requires three pieces of information to be entered.
These are the probe millivolts, probe temperature, and either the COF or the PF (depending
on the type of atmosphere controller you are using). The probe millivolts and probe
temperatures are entered on the right side of the page. Before entering either a COF or a PF,
you will need to determine the manufacturer of the atmosphere control instrument you are
using. If SSi, Honeywell, Barber Colman, Yokogawa, or anyone other than Marathon
manufactures the instrument, then it will contain a CO Factor Adjustment variable. If you are
using a Marathon Sensors instrument, then this variable is called a Process Factor
Adjustment. Only one of these (COF or PF) will be used at any one time, and the other will
not be relevant. If your instrument has a CO Factor Adjustment variable, then use the arrow
keys to go to the appropriate location and type in the value that is stored in your atmosphere
control instrument. After the value is entered, you will see an * appear next to the number.
This lets you know that the CO Factor is being used for the calculations, not the Process
Factor. If your instrument has a Process Factor Adjustment variable, then this value should
be entered in the PF= slot, which will result in the * appearing by the number that you
entered.
The calculation of probe % carbon is no different from the % carbon as displayed on the
atmosphere controller. The algorithm used by both instruments in their calculations is
identical. The reason the information is entered into the PGA is not to calculate the probe %
carbon, but to enable the PGA to compute the suggested COF / PF. Without knowing the
current instrument values, it cannot compute the suggested values.
What is a CO Factor or a Process Factor?
The carbon probe is measuring the amount of oxygen in the atmosphere. Knowing the
amount of oxygen, the atmosphere controller can determine the percentage of carbon. The
calculation that the instrument uses to translate oxygen concentration into % carbon is based
on a theoretically pure atmosphere being present in the furnace. The composition of this
theoretically pure atmosphere is 40% hydrogen (H2), 40% nitrogen (N2), and 20% carbon
monoxide (CO). In many situations, the measured amount of CO is less than the theoretically
exact 20%. This can be due to a variety of factors including seasonal changes in natural gas
composition and incomplete gas cracking in an endothermic generator. The CO Factor and
Process Factor adjustments are intended to make adjustments to the calculation to
accommodate differences between theoretical and actual gas compositions.
Suggested COF / PF
Between the two methods of determining % carbon (probe and infrared), the infrared is
considered to be more accurate. This is because the infrared analyzer evaluates the levels of
three gases (CO, CO2, and CH4) to make its calculation, instead of just using % oxygen like
the probe does. At the bottom of the middle display column, you will see suggested COF and
PF values. These values are determined by making a comparison between where the probe
is actually reading and where it should be reading. The suggested COF and PF values can be
entered into your atmosphere controller to make it display the same % carbon reading as the
PGA3500. By performing periodic evaluations with the PGA3500 and making the suggested
modifications to the adjustment factor in the atmosphere controller, you can be assured that
your continuous source of process data (the probe) is as accurate as possible. Of course,
SSi Manual 4559 Page 11 of 26 3-Gas Analyzer PGA3500
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large changes in CO Factor or Process Factor should be verified by shim stock analysis or
other means to confirm the significance of the change.
Combustion Display – Menu Page 3
The combustion display shows the current
reading in % excess oxygen. Also shown is
the relative flow rate of the sample by a fuel
gauge on the left-hand side of the screen.
The sample pump may be turned on or off
by pressing the circular arrow key.
This screen is not intended to measure
oxygen as accurately as a probe. It is
intended only to serve as a method of
checking to see if there is oxygen
contamination in the sample. This sensor
measures oxygen to a tenth of a percent,
where a probe will provide accuracy in the
parts per million.
Pump Control - Menu Page 4
The pump control page is used to set the pump
mode. The sample pump mode can be changed from
OFF to ON to AUTO by pressing the circular arrow
key. Auto mode will turn the pump on when the flow
is below approximately 1.5 SCFH and off when it is
above approximately 1.5 SCFH. Also shown is the
relative flow rate of the sample by a fuel gauge on
the left-hand side of the screen. There is also a
traditional flow meter located in the lid of the PGA.
Although the flow indicator on the screen has been
calibrated at the factory, the most accurate flow
measurements should be taken with the flow meter
inside the lid.
Set Display Values – Menu Page 5
This page is used to adjust the display values.
The backlight brightness and contrast are
factory set to 51%, which should be
appropriate for most viewing conditions. Their
values can range from 0 to 100% if desired.
Also shown on this page is the Backlight ON
Time. This is a power saving feature that will
enhance battery life by turning the backlight
off if no buttons are pressed within a predetermined number of minutes. When it turns
SSi Manual 4559 Page 12 of 26 3-Gas Analyzer PGA3500
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off, the instrument still operates fully, but the display is more difficult to read. To restore the
backlight, press any key. To disable this function, enter 0 and the backlight will be always
on.
Help Page - Menu Page 6
This page can be used as a reference to briefly describe the functions of the various buttons
on the keypad. This manual is a better resource, however if it is not available this screen will
be able to offer information that will help in navigating through the screens on the PGA3500.
Below is the text for the Help page:
Use the up and down arrows to see all. To view the list of menu pages, go to the menu
screen by pressing the 'Esc' button. This button will toggle between the IR Status Display
(Screen 1) and the Menu List. To access a specific menu, use the arrow keys to scroll up or
down to the desired selection and press 'Enter'. Or, if you already know the number of the
screen, simply type it and press 'Enter'. The circular arrow button on the bottom right side of
the keypad will either show additional data for that screen or it will change the pump status.
To enter data on a specific screen, highlight the desired location by using the up and down
arrow keys. Then enter the number using the numeric keypad and pressing 'Enter'. Pressing
the 'ESC' button once will clear any typed data that is on the screen. Pressing it again will
return you to the menu list, and pressing it one more time will return you back to Screen #1,
the main page. For additional information on the operation of this instrument, please
consult the Product Manual, which can be downloaded at no cost from our website at
www.supersystems.com if necessary.
Calibration Dates and Run Times - Menu Page 7
This page shows the most recent calibration
dates, as well as the amount of time that has
elapsed since each calibration. Time is
shown in hours and minutes. These dates do
not need to be set after calibration since they
will be set automatically whenever a
calibration is performed.
calibration dates to be entered, the internal
clock must be set correctly (see menu page
16 – Set The Date and Time)
Language / Lengua – Menu Page 8
This menu page will allow the user to select
a different language for most of the
displayed words. These language files are
stored on the PGA drive and should not be
modified by the user unless directed to by a
Super Systems Inc employee.
Modification of the language files can
produce unwanted or undesirable results
Use the up or down arrow keys to select the
Warning:
.
Note: For accurate
.
SSi Manual 4559 Page 13 of 26 3-Gas Analyzer PGA3500
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desired language and then press the Enter key. The selected language will be displayed
above the list of languages.
Battery Status – Menu Page 9
This page displays information regarding the
instrument power supply.
The Battery Voltage shows the DC voltage
from the battery. It will read higher when
the instrument is plugged in, so a true
measurement should be taken when it is not
connected to AC power.
The Battery Condition will show the battery
,
status as Very Low
on the battery voltage. When the unit is
plugged in, it will show Charging.
The DC Supply is the amount of power that is being generated by the internal power supply.
This will be 0 when it is not plugged in.
The Internal Supply is the amount of voltage that the instrument is seeing. It is the greater
of the battery voltage and the DC supply.
If the instrument has been left unattended in the on position, the battery may be completely
dead. It may be possible to recharge the battery but it will take a few days to accomplish
this. By leaving the instrument plugged in and periodically checking the battery voltage to
see if it is increasing, you will be able to determine if the battery is taking a charge. Keep in
mind that it could take three or four days if the battery is completely dead.
It is recommended that the instrument not be plugged in after every use. The battery will
last longer if it is fully or mostly discharged before it is charged, so it is good practice to only
charge it after it has been used for three or four hours or more. If the battery gets low, a
warning message will appear on the screen, followed by an estimate of the amount of time
until it runs out of power. You will always have at least an hour of run time when you first
see this message.
When it is plugged in to recharge, the instrument can still be used. The unit will recharge
and operate at the same time.
Low, or OK depending
About/Sign-On – Menu Page 10
This page is the sign-on screen that shows the
SSi logo and phone number. Also shown is the
unit serial number, the date of the last factory
calibration, and the number of hours and
minutes that the instrument has been in use
since the last factory calibration.
SSi Manual 4559 Page 14 of 26 3-Gas Analyzer PGA3500
Revision Level - D
Revision Display – Menu Page 11
This page shows the firmware revision levels
for the instrument. Although the user
cannot modify this information, it may be
helpful to report when contacting Super
Systems for support.
Logged Data Start Date – Menu Page 12
Data is continuously logged in the
PGA3500, so there is no need to turn it on
or off. It is always on. This page can be
used to view data from a specific date,
with the default setting being the current
hour of the current date.
Logged Data File – Menu Page 13
Each minute, there are 15 points of data
collected. The time of each data point is
shown along the left-hand side of the
screen. The arrow buttons will scroll
backwards and forwards in time, however it
will not allow you to view data beyond the
current time. Although 15 data points are
stored, only 5 are visible at one time. The
others can be accessed by pressing the
circular arrow key at the bottom right of
the keypad. When the screen is first
accessed, the following five variables are
shown:
(00) IR%C – Percent Carbon as
computed by the PGA3500
(01) IRTC – Temperature used by the PGA3500 to compute the Percent Carbon
(02) %CO – Percent Carbon Monoxide
(03) %CO2 – Percent Carbon Dioxide
(04) %CH4 – Percent Methane / Natural Gas
SSi Manual 4559 Page 15 of 26 3-Gas Analyzer PGA3500
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Pressing the circular arrow button will
display the following five variables:
PB%C – Percent Carbon as computed by
the probe
PBTC – Probe Thermocouple
(Temperature)
PBMV – Probe Millivolts
PBCF – Probe CO Factor
PBPF – Probe Process Factor
By pressing the circular arrow button
again, the following screen is shown:
The abbreviated headings for the
columns represent:
%O2 – Percent Oxygen
FLOW – Flow Rate (0 to 100
represents 0.0 to 2.0 SCFH)
ShmF – Infrared Shim Factor
Adjustment Setting
CH4F – Infrared CH4 Factor
Adjustment Setting
IRkP – Sample Pressure in KiloPascals
Pressing the circular arrow button
again will return you to the first set of
variables.
Session - Menu Page 14
Session page will allow the user to
start a session on the PGA. A session
will allow the user to identify the
operation of the PGA and break all of
the logged data into manageable
sections. Sessions can be viewed on
a computer with the XGA Viewer
software. For instance, when testing
a generator, the user can start a
session that will indicate that the
generator is being tested, when it
was tested, where it was tested, how
long it was tested, and who did the
testing. The first line, “Initiate session (1):” will allow the user to start a session on the PGA
Note: Even though this is the first line on the screen, it will be the last line used, since all of
the data entry lines are below
the list of operators in the PGA. The user can either enter a number corresponding to the
location of the operator in the list, or the user can cycle through the operators by pressing
the circular arrow key. For example, if the list of operators was: J. Doe, B. Smith, and C.
SSi Manual 4559 Page 16 of 26 3-Gas Analyzer PGA3500
Revision Level - D
. The next line, “Operator:” will allow the user to scroll through
.
Jones, then to select B. Smith, the user can enter a 2 while the “Operator” line is highlighted,
or the user can press the circular arrow key until B. Smith is shown. The next line, “Test
number:” will allow the user to enter a test number, which will be used for identification
purposes. The test number can be between 1 and 999. The next line, “Equipment name:”
will allow the user to select the equipment name being used, i.e., Furnace 1, Furnace 2,
Generator, etc. The process for selecting an equipment name is the same as selecting an
operator. The next line, “Equipment type:” will allow the user to select the equipment type
being used, i.e., Furnace, Generator, etc. The process for selecting an equipment type is the
same as selecting an operator. The next line, “Location:” will allow the user to select the
location where the PGA is being used, i.e., Main Plant, Zone 1, etc. The location can be as
broad or as specific as desired. The locations can be cities, plants, or even sections of the
same plant. The process for selecting a location is the same as selecting an operator. Once
all of the information has been entered, the user can scroll back up to the top line, enter a 1,
and then press the Enter to begin the session. The list of operators, equipment names,
equipment types, and locations can all be modified and added through the XGA Viewer
software.
Once a session has started, the second
page of the session menu will be
displayed. From this page, the user can
add a note to the session, or end the
session. Once again, the first line will be
one of the last lines to be accessed since
there can be some data entry involved
with adding a note. To add a note, scroll
down to the second line, “Desired note”.
The process for selecting a note is the
same as selecting an operator from the
first page. The notes are kept in a list that
can be managed by the XGA Viewer software. Once the note has been selected, scroll back
up to the first line, press a 1, and then press the Enter key to add the note. To end the
session, scroll to the first line, press a 2, and then press the Enter key. The “Session
started:” line will let the user know when the session was started.
Sampling Parameters - Menu Page 15
This menu page will allow the user to set
up the parameters that will affect when
the pump will be turned on or off (only
when pump is in automatic mode) and it
will determine the parameters for the
automatic adjustment of the COF/PF.
The Minimum Temp is the lowest
temperature that the instrument will
sample from. When the temperature
drops below this value, the COF/PF
adjustment will stop and the sample
pump will turn off only if the pump is set
to automatic mode. See the section
change the mode of the pump. To use this feature, the instrument should be communicating
SSi Manual 4559 Page 17 of 26 3-Gas Analyzer PGA3500
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Pump Control – Menu Page 4
for information on how to
with an instrument that can provide real-time temperature data. The purpose of this function
is to prevent the instrument from pulling a bad sample, which could potentially damage the
sensors. The minimum temperature should always be slightly higher than the lowest possible
process temperature. The range of values for the Minimum Temp is 0 to 2000.
The Minimum mV is the millivolt set point that will stop the COF/PF adjustment. This will
prevent adjustments from being made when the proper conditions are not met. The minimum
millivolts set point should be slightly higher than the minimum millivoltage that is expected.
The range of values for the Minimum mV is 0 to 2000.
The Maximum Adjustment is the largest increment of change that will be applied to automatic
COF/PF adjustments. This will dictate the size of the steps the instrument takes when it
adjusts the COF or PF of the control instrument. A higher value will result in more speed in
achieving the desired set point, but a lower value will result in a smoother approach. The
Maximum Adjustment feature should be coordinated with the Update Interval time to achieve
the desired responsiveness. The range of values for the Maximum Adjustment is 0 to 20.
The Maximum COF/PF establishes the upper allowable limit for the COF/PF. For example, if
this is set to 300, then the instrument will make changes to the COF/PF until it is at 300, but
it will not go any higher. The value will range from 0 to 999.
The Minimum COF/PF establishes the lower allowable limit for the COF/PF. For example, if
this is set to 100, then the instrument will make changes to the COF/PF until it is at 100, but
it will not go any lower. The value will range from 0 to 999
.
The IR Mode is a selection to determine if the instrument is running in Automatic or Manual
mode. When in Monitor mode, no changes will be made to the COF/PF of the control
instrument. There are two Automatic modes to select from. COF/PF Adj. %C will make
adjustments to the COF/PF in the atmosphere controller based on the calculated percent
carbon. This is the preferred method of adjustment. The other Automatic mode, COF/PF
adj. CO, will make adjustments based only on the measured level of CO and not on the
carbon calculation. The three options are:
Monitor
COF/PF Adj. %C
COF/PF adj. CO
To cycle between each selection, press the circular arrow key or enter the number that
corresponds to the option’s position in the list and press Enter, where Monitor is at position 0
and COF/PF adj. CO is at position 2.
The On Delay determines the amount of time it takes for the pump to turn on after both of
the operating parameters (temperature and millivolts) have been met. The value will range
from 0 to 60 minutes.
The Off Delay determines the amount of time it takes for the pump to turn off after either of
the operating parameters (temperature and millivolts) falls outside of the pre-defined
boundaries. The value will range from 0 to 60 minutes.
The Update Interval determines the amount of time between automatic updates of the
COF/PF on the control instrument. This is adjustable in one-minute increments. It is
recommended that the Update Interval be set to one (1) minute, and the Maximum
Adjustment set to one (1) point. This will allow the COF/PF to be adjusted frequently, but
only a small amount at a time, which will result in smooth operation. The value will range
from 0 to 20.
The Sample Delay determines the amount of time the PGA will wait to continue to adjustment
of the COF or the PF once the pump has turned on. The range of values is 0 to 30.
Example – The following will show how to set up the sampling parameters of:
Minimum Temp – 1500
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Minimum mV – 1200
Maximum Adjustment – 1
Maximum COF/PF – 250
Minimum COF/PF – 75
IR mode – COF/PF Adj. %C
On Delay – 10.5 minutes
Off Delay – 5 minutes
Update Interval – 1 minute
Sample Delay – 30 seconds
When the menu screen first displays, the Minimum Temp field is already highlighted. Enter a
1500 and press Enter. Press the down arrow key once to highlight the Minimum mV field.
Enter a 1200 and press Enter. Press the down arrow key once to highlight the Maximum
Adjustment field. Enter a 1 and press Enter. Press the down arrow key once to highlight the
Maximum COF/PF field. Enter a 250 and press Enter. Press the down arrow key once to
highlight the Minimum COF/PF field. Enter a 75 and press Enter. Press the down arrow key
once to highlight the IR Mode field. Enter a 1 and press Enter (Note – the screen will display
COF/PF Adj. %C). Press the down arrow key once to highlight the On Delay field. Enter a
10.5 and press Enter. Press the down arrow key once to highlight the Off Delay field. Enter
a 5 and press Enter. Press the down arrow key once to highlight the Update Interval field.
Enter a 1 and press Enter. Press the down arrow key once to highlight the Sample Delay
field. Enter a 0.5 and press Enter.
Set The Date and Time - Menu Page 16
This page is used to set the internal clock
and calendar. Select a number that you
would like to change by using the up and
down arrow buttons. Then type in the
number and press Enter. No changes will
take place until the seconds are set, which
starts the clock under the new settings.
Numbers 1 through 12 changes the month.
The days of the week are entered using 0
for Sunday through 6 for Saturday. Hours
are entered in 24-hour format, i.e. 8 for
8AM and 14 for 2PM.
Port Setup - Menu Page 17
Port Setup is used to set the
parameters for the communications
ports. The factory default settings
are shown, and they should not need
to be changed by the operator.
SSi Manual 4559 Page 19 of 26 3-Gas Analyzer PGA3500
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Zero Calibration – Menu Page 18
This page is used to zero the IR cells. It is
very important to be sure that the sample
gas is a good zero especially for CO2.
Ambient air has nominal percentage of
CO2, which should not be present when
performing a zero calibration. It is
recommended that 99.9% pure nitrogen
be used for zeroing the PGA3500. If there
is no nitrogen present, the CO2 Scrubber
(P/N 13112) can be used to remove the
CO2 from ambient air. The sample gas flow rate should be between 1 and 1.5 SCFH.
When viewing this screen, the current measured values are shown at the left under the
heading
column is
values, followed by a comment. This comment can either be OK, ?OK, or BAD, depending
on how far apart the values are. If the difference is between 0 and 10% of the span value,
then it will be OK and the calibration will proceed without interruption. If the difference is
between 10% and 20%, it will be ?OK, and a warning message will be displayed. Pressing
Enter will allow the calibration to continue. If the value is more than 20% out, it will be
BAD and the calibration will not be allowed to proceed. If this occurs, check to make sure
that you are using the correct gas and that there is adequate flow. If it is still not operating
properly contact SSi for additional support.
It is possible to calibrate one, two, or all three sensors. The default setting is to calibrate all
three, however if you do not want to calibrate one of the sensors you can use the up and
down arrows to access the sensor that you do not want to calibrate, and press Enter over
the existing Yes. This will change it to No, and that sensor will not be calibrated.
To proceed with the calibration of one or more sensors, use the arrow key to move to the
Start button and press Enter. Timers will count down approximately two minutes and at the
conclusion the sensors will be calibrated.
WARNING: Do not pressurize PGA3500 with compressed gas. Always start the
flow of Nitrogen and regulate prior to connecting to PGA3500 inlet.
Actual
, while the desired values will be in the center column,
Status
, and this shows the percentage difference between the actual and desired
Zero Gas
. The final
O2 Cell Calibration – Menu Page 19
O2 Cell Calibration is used to calibrate
the oxygen sensor. The oxygen sensor is
calibrated using air (20.9% O
reference. If the oxygen cell output is
outside of a 30% band then the message
REPLACE O
CELL! will appear near the
2
bottom of the screen. When calibrating
the O
sensor, no special gas is required,
2
only fresh ambient air. It is better to
perform this calibration in an office or
SSi Manual 4559 Page 20 of 26 3-Gas Analyzer PGA3500
Revision Level - D
) as the
2
outside to be sure that the process gas does not influence the ambient air. After the pump
has been on for long enough for the readings to stabilize (approximately one minute), press
the Enter key to begin the calibration process. A calibration complete message will appear
when the calibration is finished.
Communications Setup – Menu Page 20
The menu page will allow the user to
set up the communications settings for
the PGA.
The Port Usage determines how the
PGA will communicate. The options are
either RS485 Host Port or Modbus.
These can be changed either by
pressing the circular arrow key to cycle
through the options, or by entering a
number which corresponds to the
option’s position in the list, where
RS485 Host Port is at position 0, and
Modbus is at position 1.
The Port Baud Rate determines how fast the PGA will communicate. The options with the
position number are:
Position Rate Position Rate
0 1200 9 76800
1 2400 10 115200
2 4800 11 230400
3 9600 12 460800
4 14400 13 921600
5 19200
6 28800
7 38400
8 57600
To change the baud rate, press the circular arrow key until the desired option is reached, or
enter in the position number from the list above and press Enter to select the desired option.
The ATM Inst Type is the make and model of the instrument that will be supplying the PGA
with information on: probe temperature, probe millivolts, and COF/PF. The options with the
position number are:
Position Type Description
0 SSI AC20 Super Systems AC20
1 Yoko 750 Yokogawa 750
2 UDC 3300 Honeywell UDC 3300
3 DP 1 Mod Marathon Sensors DualPro – Modbus Protocol Loop 1
4 DP 2 Mod Marathon Sensors DualPro – Modbus Protocol Loop 2
5 9200 lp Super Systems Model 9200 Loop 1
To change the instrument type, press the circular arrow key to cycle through the options, or
press the option’s position number and press Enter.
The ATM Inst Addr is the address of the ATM Inst. To change the address, enter the new
value and press Enter. The values can range from 0 to 250.
SSi Manual 4559 Page 21 of 26 3-Gas Analyzer PGA3500
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The Furn TC Inst Type is the make and model of the instrument that will be supplying the
PGA with information on furnace temperature. If there is no instrument associated with this
input, the PGA will use the value from the probe temperature (ATM Inst Type) as the furnace
temperature. The options with the position number are:
Position Type Description
0 SSI 7EK Super Systems 7EK
1 Yoko 750 Yokogawa 750
2 UDC 3300 Honeywell UDC 3300
3 DP 1 Mod Marathon Sensors DualPro – Modbus Protocol Loop 1
4 DP 2 Mod Marathon Sensors DualPro – Modbus Protocol Loop 2
5 9200 lp1 Super Systems Model 9200 Loop 1
6 9200 lp2 Super Systems Model 9200 Loop 2
7 9200 lp3 Super Systems Model 9200 Loop 3
8 9100 lp2 Super Systems Model 9100 Loop 2
9 SSI_DO0 Super Systems DAC Output Board Channel 0
10 SSI_DO1 Super Systems DAC Output Board Channel 1
11 SSI_DO2 Super Systems DAC Output Board Channel 2
12 SSI_DO3 Super Systems DAC Output Board Channel 3
To change the instrument type, press the circular arrow key to cycle through the options, or
press the option’s position number and press Enter.
The Furn TC Inst Addr is the address of the Furn TC Inst. To change the address, enter the
new value and press Enter. The values can range from 0 to 250.
Calibrate Flow Meter – Menu Page 22
This page is used to calibrate the internal
digital flow meter. This will already be
performed at the factory, however
adjustments are simple if necessary. First,
with the pump off, press the up arrow key to
set the Zero Factor. Next, turn the pump on
by pressing the circular arrow button at the
bottom right of the keypad. The actual flow
amount can be viewed on the flow meter
inside the lid of the case. Adjust the valve
on the flow meter to set the flow at 1.5
SCFH. Then type in 75 followed by Enter.
This will set the flow meter to equate 1.5 SCFH to 75% of the maximum of the digital flow
meter.
Calculation Factors - Menu Page 23
Calculation Factors allows for the entry of data that the
operator should not normally access. The first two
items are the IR shim factor and the CH4 Factor, both
of which are used in the calculation of % carbon. The
third item is a Pressure Factor, which should contain a
value of 0, which is “Off”. These values should only be
SSi Manual 4559 Page 22 of 26 3-Gas Analyzer PGA3500
Revision Level - D
changed after determining that additional adjustments are required based on the specific
conditions and equipment at your facility. Please contact Super Systems for help with
adjusting these pre-set values.
Span Calibration – Menu Page 24
This page is used to span calibrate the IR
cells. It is very important to be sure that a
Certified Primary Standard sample gas within
the noted specifications is used. The nominal
composition of this gas should be:
20% CO (Carbon Monoxide)
1% CO2 (Carbon Dioxide)
6% CH4 (Methane or Natural Gas)
40% H2 (Hydrogen)
Balance N2 (Nitrogen)
When viewing this screen, the current measured values are shown at the left under the
heading
column is
values, followed by a comment. This comment can either be OK, ?OK, or BAD, depending
on how far apart the values are. If the difference is between 0 and 10% of the span value,
then it will be OK and the calibration will proceed without interruption. If the difference is
between 10% and 20%, it will be ?OK, and a warning message will be displayed. Pressing
Enter will allow the calibration to continue. If the value is more than 20% out, it will be
BAD and the calibration will not be allowed to proceed. If this occurs, check to make sure
that you are using the correct gas and that there is adequate flow. If it is still not operating
properly contact SSi for additional support.
To proceed with the calibration of one or more sensors, use the up and down arrows and the
numeric keypad to enter the specific values of each gas. These will be listed on the
calibration cylinder. It is possible to calibrate one, two, or all three sensors. The default
setting is to calibrate all three, however if you do not want to calibrate one of the sensors you
can use the up and down arrows to access the sensor that you do not want to calibrate, and
press Enter over the existing Yes. This will change it to No, and that sensor will not be
calibrated.
When this data has been entered, use the arrow key to move to the Start button and press
Enter. Timers will count down approximately two minutes and at the conclusion the sensors
will be calibrated.
Actual
, while the desired values will be in the center column,
Status
, and this shows the percentage difference between the actual and desired
WARNING: Do not pressurize PGA3500 with compressed gas. Always start the
flow of Nitrogen and regulate prior to connecting to PGA3500 inlet.
Span Gas
. The final
Set Pass Codes - Menu Page 25
This page is used to change the pass code for menu screens 16 and higher. For screens 1
through 15, no pass code is required to access the screen. Menu screens 16 through 21 are
considered Supervisor Level, and they require the Level 1 pass code. Menu screens 22
through 29 are considered Configuration Level, and they require the Level 2 pass code. The
SSi Manual 4559 Page 23 of 26 3-Gas Analyzer PGA3500
Revision Level - D
default setting for Level 1 is 1, and the default
setting for Level 2 is 2. Either of these can be
changed to any number between 0 and 512.
Please note that the Level 2 (Configuration) pass
code will also work on all Level 1 menus, so in the
default settings entering a 2 will give you access
to all available menus.
The Level 3 menus are not visible, and SSi uses
them when the instrument is being set up prior to
shipment.
Set IP Address- Menu Page 26
This page is used to setup the Ethernet
communications address. The instrument
does not have DHCP, therefore a fixed IP
address must be assigned.
General Information - Menu Page 28
This menu page will display some general
information about the PGA. This screen is
for display purposes only, so no information
can be entered on the screen.
The Sample Status will display the
status of the pump. If the pump is not
running, the text will display
SAMPLING OFF. If the pump is
running, then the text will display
SAMPLING ON.
The ATM Inst COM status will display
the status of the atmosphere
instrument’s communications. The status of the communications can be either OK or
BAD.
The Furn TC Inst COM status will display the status of the furnace TC instrument’s
communications. The status of the communications can be either OK or BAD.
SSi Manual 4559 Page 24 of 26 3-Gas Analyzer PGA3500
Revision Level - D
PPGGAA33550000 SSppaarree PPaarrttss
• Factory Calibration Part Number 13113
• Cylinder of Zero Calibration Gas Part Number 30054
• Cylinder of Span Calibration Gas Part Number 13084
• Bowl Filter Assembly (Including Element) Part Number 37048
• Bowl Filter Element Media Replacement (10/Pack) Part Number 31027
• Flexible Sample Tubing Assembly with Filter Part Number 20315
• Replacement In-Line Filter Part Number 31033
• Flow Meter Part Number 36033
• CO
• Sampling Wand Assembly Part Number 20263
• PGA3500 Battery Part Number 32012
• Replacement box and custom-fit foam Part Number 23075
Scrubber Part Number 13112
2
SSi Manual 4559 Page 25 of 26 3-Gas Analyzer PGA3500
Revision Level - D
RReevviissiioonn HHiissttoorryy
Rev. Description Date MCO #
Initial Release
-
SSi Address and General Update
A
B Added/Revised “Spare Parts List”
C Added “MCO #” section in Revision History;
Updated logo on title page; Updated parts
list; Changed picture sizes; Added
functionality for menus: 8, 14, 15, 20, 28;
Updated menu 6 to include help text;
Updated screen shot for menu 11; Moved
the “Typical Diagnostic Uses for the
PGA3500” section to the beginning of the
manual
D Changed part number 20104 to 20315 in
“PGA3500 Spare Parts” section
03-15-2005 N/A
05-18-2005 2035
01-04-2007 2041
10-04-2007 2050
08-13-2008 2066
SSi Manual 4559 Page 26 of 26 3-Gas Analyzer PGA3500
Revision Level - D
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