Operation Manual - Whaley Food Service
Contents
1. Super Systems Inc Page 26 of 33 PGA3510 Operations Manual IMPORTANT SSi strongly recommends that anyone who performs these calibrations have previous experience with and strong working knowledge of this type of procedure If in doubt contact SSi at 800 666 4330 to request assistance or to have the unit returned to the factory for calibration An improperly performed calibration will significantly impact temperature readings in a negative Way To perform a millivolt calibration Zero and Span Needed Copper wire not thermocouple wire millivolt sourcing device 1 Ze 3 SE a 9 Open the Analog Input Calibration page Make sure that the selected input at the top of the screen is mV Prepare the millivolt sourcing device This device should be capable of sourcing a specified raw voltage between 0 and 1 volt Connect the copper wire from the millivolt device to the white input jack labeled CU uncompensated on the side of the case Tap Zero on the touch screen Configure the millivolt sourcing device to deliver zero millivolts Wait for the Current Value displayed on the screen to get as close to zero as possible Tap Calibrate Tap Yes when asked if you want to proceed with the calibration A progress indicator will appear Select pt O Zero O Span Current Value 0 1 mV 17 seconds remaining Return When the process completes Zero calibration Is finished 10 Tap Spa2. NOTE This field will also change the number of decimal places used for the Valve Maximum field in the Valve Setup menu D Gas Selection Drop Down List This drop down list allows you to select the gas used in the selected flow control valve If used valve 1 must be used with N and valve 2 must be used with NH these are fixed Valve 3 may be used with Dissociated Ammonia DA NH3 a miscellaneous gas Misc endothermic gas Endo or CO Valve 4 may be used with H NHz a miscellaneous gas Misc endothermic gas Endo or CO E Enabled checkbox If this box is checked the selected flow control valve number is enabled and will be displayed on the Nitrider Calculation page If it is not checked the valve is disabled it will not be displayed on the Nitrider Calculation page When finished with valve setup tap the Done button Super Systems Inc Page 30 of 33 PGA3510 Operations Manual Parts List The following items can be purchased as needed for the PGA3510 13548 3 Gas PGA for Corrosive Gases Standard plus compatibility with NH gas 13549 4 Gas PGA for Corrosive Gases Standard plus H measurement and compatibility with NH gas Super Systems Inc Page 31 of 33 PGA3510 Operations Manual 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 fo
3. Page 8 of 33 PGA3510 Operations Manual The right pointing green arrow button o will move the chart s view forward in time by the specified chart interval The right pointing arrow with the vertical line next to it button will toggle between viewing the chart in or out of real time 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 a couple of seconds The sub menu will have the following options available Zoom Restore Add Note Data and Exit IR YC 2 00 C 0 00 C fe 1700 H 0 08 AA 0 020 0 80 C ae Add Note Data eS 7 0 00 C somes e noo ns 5 11 AM 5 59 AM 6 47 AM 7 35AM 8 23AM jo ja 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 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 initial chart screen The Add Note option allows the operator to enter a note on the chart similar to writing on a paper chart The note is available when the chart is printed out using the utility software inc
4. mixture of endothermic gas to infer the percent carbon whereas the gas analyzer will measure the exact composition of the process gas The percent carbon determined by the gas analyzer can then be used to adjust the carbon percentage determined by the oxygen probe Chart The 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 flash card The vertical timelines change as the time changes on the screen The function buttons run along the bottom of the screen 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 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 Le will move the chart s view backward in time by the specified chart interval The chart interval button J 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 Super Systems Inc
5. the side of the case 9 Enter the desired temperature value based on which to deliver a corresponding voltage 6 Configure the temperature sourcing device to deliver the proper voltage 7 Wait for the Current Value displayed on the screen to get as close to the target voltage as possible 8 Tap Calibrate Tap Yes when asked if you want to proceed with the calibration A progress indicator will appear 9 When the process completes temperature calibration Is finished Valve Setup The PGA3510 uses four flow control valves for nitriding gas analysis These valves are enabled and set up in the Valve Setup window Super Systems Inc Page 29 of 33 PGA3510 Operations Manual Valve Setup Valve Maximum B Valve Decimal Place C Gas D E r Enabled The Valve Setup window contains the following items A Valve Selection Drop Down List Using this drop down list you can select the valve number through 4 that you want to configure B Valve Maximum This field is used to set the maximum valve that can be entered for the valve gas flow Tap on the field to change it C Valve Decimal Place This field is used to set the number of decimal places that will be used in the valve gas flow value in the Nitrider Calculation page For example if the valve decimal place is set to 1 in this menu and 600 is entered for valve 1 flow on the Nitrider Calculation page the displayed value will be 60 0
6. 01 H2 38 49 a0 SESSION NOT ENABLED COMMS N A 02 0 B aro K C Menu Carbon Celculation D E F G HI J A Measured values of CO CO and CH land H if the H sensor is present B Pump status indicator Button to change pump status C Button to access menu list D Session status indicator E Temperature Instrument Temperature indicator F Button for Carbon Calculation screen G Automatic Carbon Calculation Adjustment indicator H External Instrument Communications status indicator Measured value of Oxygen J Button for Trend Chart screen K Numeric Flow indicator L Visual Flow indicator Super Systems Inc Page 6 of 33 PGA3510 Operations Manual Pressing the Return button at the bottom right of the operator interface on any screen will take the display to the default It may be necessary to press the Return button multiple times Pump Operation Initially the pump will be off The pump should remain off while sampling an endothermic generator or any other atmosphere under positive pressure The pump should also remain off during calibration For proper operation the flow of gas through the sensors should be between 1 0 and 2 0 SCFH If the flow meter on the right of the screen or on the inside of the lid does not indicate sufficient flow turn the pump on When accessed from the main screen the pump has two possible modes On and Off Pump Control Pump mode Calibrate flow meter Retu
7. a a de ed de A te 26 USE ds o ates 26 Set User Cal Load User Calera dada 26 Calor LO a ci 26 Analog Input alba aria 26 VaWe UN o od 29 A caster cecestercsaeateecnsn 5 460 E E ere 31 AA a 1 nee me SP OE Oe gC ee eS ee ee eae noc ene 32 PROVISO Weed TONNES ne ee cena ee de ie ee user ri 33 Super Systems Inc Page 3 of 33 PGA3510 Operations Manual Introduction The Model PGA3510 see part numbers in the Parts List on page 31 is a portable Multi Gas IR analyzer with an Oxygen 0 cell It measures Carbon Monoxide CO Carbon Dioxide CO and Natural Gas CH typically found in an endothermic atmosphere The measurement of these gases combined with furnace temperature information allows the PGA3510 to calculate the percent Carbon C of the measured gas A Hydrogen H sensor can also be incorporated as an option to provide a more complete picture of the measured gas For nitriding and ferritic nitrocarburizing FNC applications the PGA3510 can calculate carburizing potential K and nitriding potential Ky Finally the PGA3510 can be configured for compatibility with environments containing ammonia NH gas NH compatibility must be specifically requested when the PGA3510 is ordered IMPORTANT Do not use a PGA3510 for gas analysis with NH3 containing gas if the PGA3510 has not been configured with NH compatibility Any use of a non NH compatible PGA3510 with NH3 containing gas will void the product warranty
8. can be sorted by End Time Equipment Name or Operator Name by touching the header of each column To see the details of any session highlight it by touching it and then press Detail This will display a graphical representation of the data from the selected session 40221 4703445718 Sele IR C 2 12 2010 SSi PGA3510 2 12 2010 X 2 00 C 11 05 AM 0 23 C 1 60 C lo tl Ey 1701 00 23 56 h A 1 110 sl EIN 12 15 f ats a 5 e bhe T A R 10 16 AM 10 28 AM 10 40 AM 10 52 AM 11 04 AM 2 pelo po For more information on navigating the Chart Screen see the Chart section of this manual To leave the Chart view press the red X in the upper right hand corner of the screen Super Systems Inc Page 14 of 33 PGA3510 Operations Manual Pump Control The Pump Control screen will identify and allow the modification of the pump status On or Off Pump Control Pump Status Return Sensor Calibration Sensor Calibration Span Calibration Actual 0 00 o 0 006 1 0 05 s Last Zero Calibration 1 1 1980 2 days 38 minutes Last Span Calibration 1 1 1980 1 day 23 hours 57 minutes Pump should be off when using pressurized cylinders of gas a e Enter Cal Mode Calibrate O2 Return Two types of calibrations can be performed on the NDIR sensor Zero and Span The Zero calibration should be performed with a gas that has none of the measured gases In it Ideally this would be pure
9. 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 IMPORTANT Do not use a PGA3510 for gas analysis with NH containing gas if the PGA3510 has not been configured with NH compatibility Any use of a non NH compatible PGA3510 with NH containing gas will void the product warranty Super Systems Inc Page 32 of 33 PGA3510 Operations Manual Revision History Date MCO Initial Release Please Reference MCO 2084 9 1 2011 2084 Updated for revised capability of H sensor 11 16 2012 2107 Updated for added nitriding calculations available compatibility with 2 7 2014 2135 ammonia gas Updated parts list Tools menu updated as needed Super Systems Inc Page 33 of 33
10. I to obtain the access code that is specific for the date and time shown on the instrument Log in using that access code Select Factory Use Only from the bottom of the menu list Select Shut Down Software followed by Yes The program will shut down and a Windows CE screen will appear Click the Start menu in the lower left corner Select Settings and then Network and Dial up Connections Select CS89001 Select the option for Specify an IP Address 0 Enter the desired IP Address Subnet Mask and Default Gateway 1 Select OK 2 Close open windows to return to the main Windows CE Screen 3 Double click on the SaveRegs icon 4 Select OK from the Registry Save Complete notification 9 Turn the instrument off and wait for the screen to turn off 6 Turn the instrument back on 7 The instrument will automatically boot up as a gas analyzer with the IP address that has been manually entered uper Systems Inc Page 20 of 33 PGA3510 Operations Manual Atmosphere Temp Sources RS485 communications can be set up to automatically enter and update data from the oxygen probe and if desired make modifications to the COF PF in the atmosphere controller Communications and Source Setup Atmosphere Temp Sources Port Usage Modbus Master Port Baud Rate 19200 Probe Temp mV Instrument SSI AC20 Probe Temp mV Instrument Address 0 Status Not configured Furnace Temp Instrument SSI EK Furn
11. Nitrogen or Argon The concentration of the Span calibration gas should closely resemble the gas that is Super Systems Inc Page 15 of 33 PGA3510 Operations Manual being measured Fora heat treating application measuring endothermic gas the ideal composition would be e CO 20 e CO 0 5 e CH 5 0 e H 40 e N Balance Since the accuracy of the calibration gas directly influences the resulting accuracy of the instrument the highest possible accuracy grade should be obtained Some gas suppliers refer to this as a Certified Primary Standard The high degree of accuracy is not required to obtain nominal values that exactly match the values shown above The accuracy is required to know the exact composition of the gas in the cylinder The actual composition will be shown on the bottle when it is delivered When flowing calibration gas is into the analyzer turn the pump off The amount of flow from the gas cylinder should be approximately 1 5 SCFH at no pressure The gas cylinders will be under high pressure so it is recommended that a two stage regulator with a low pressure secondary stage be used It is good practice to begin the flow of gas before attaching the calibration gas to the instrument This will prevent any high pressure bursts from entering the instrument Calibration gases can be obtained from Super Systems however they can also be obtained from any supplier of custom gases Hydrogen Cell Note It is recommend
12. Portable Gas Analyzer Super Systems Inc Page 4 of 33 PGA3510 Operations Manual Specifications The unit is designed and manufactured for the atmosphere heat treating industry however its uses go beyond the scope of these applications CO range 0 00 to 30 00 CO range 0 000 to 2 000 CH range 0 00 to 15 00 O range 0 1 to 25 0 H range 0 00 to 100 Note These sensors have been optimized for use at the levels normally seen in an Endothermic atmosphere The ranges can be adjusted to fit other applications For information regarding modifications to the ranges shown above please contact Super Systems Sampling method Extraction by internal pump when necessary Measurement Method CO CO CH Non Dispersive Infrared NDIR Measurement Method 0 Electrochemical Measurement Method H Thermal Conductivity Accuracy and repeatability 1 of full scale Recommended Calibration Interval Annual Flow Meter Inside case lid and also on screen AC Power Requirements 90 to 230 VAC 50 to 60 Hz 60 Watts DC Power Source 12VDC rechargeable NiCd battery with Integral charger Communications Ethernet USB A USB B RS485 Modbus Data Storage Continuous automatic data logging Data Retrieval XGA Viewer Software included or on screen Operating Temperature 32 to 122 F 0 to 50 C External Dimensions Approx 16 H X 20 L X 8 D Weight Approx 28 lbs Unpacking the Device The following item
13. SuperSystems gt PGA3510 Portable Multi Gas IR Analyzer CO CO and CH Gas Analyzer with 0 and Optional H Measurement and Carbon Dissociated Ammonia NH3 Ky and Ke Calculation Capabilities 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 800 666 4330 for assistance PGA3510 Operations Manual Super Systems Inc USA Office Corporate Headquarters 7205 Edington Drive Cincinnati OH 45249 Phone 800 666 4330 http www supersystems com Super Systems Mexico Sistemas Superiores Integrales S de RL de CV Quer taro QRO CP MEXICO 76120 Phone 52 442 410 9040 http www supersystems com Super Systems Inc Super Systems Europe Units 3 amp 4 17 Reddicap Trading Estate Sutton Coldfield West Midlands B75 7BU UNITED KINGDOM Phone 44 0 121 329 2627 http www supersystemseurope com Super Systems China No 335 XianXia Road Room 308 Shanghai CHINA 200336 Phone 86 21 5206 5701 2 http www supersystems com Page 2 of 33 PGA3510 Operations Manual Table of Contents OU do RE O SPECON ao A O Basic Operating Descrip io lo a eee Detalles cr Nara tc odias PUMP Operan td e e cn da E A A oaneecees E EE A ttc eT sen
14. a dew point that is determined through direct measurement of the moisture content of the gas When the dew point is enabled it will appear near the bottom left of the Carbon Calculation screen Language Setup The instrument language should be pre configured at Super Systems prior to shipment but can also be changed by making a selection from the drop down list For the language change to take effect the instrument must be powered off and then back on again Instrument Information These items cannot be modified they can only be viewed General Information This is information on the revision levels of various components of the instrument This can be valuable when consulting with Super Systems about issues with the instrument Calibration Dates This area describes the last time the instrument was calibrated at Super Systems plus any calibrations that have been performed since then These dates and times are automatically computed and cannot be manually entered Super Systems Inc Page 24 of 33 PGA3510 Operations Manual Power Status This screen will identify the amount of voltage that is available to the instrument and also indicate if the instrument is being charged or not When plugged in the Internal Supply Voltage will show the amount of power coming from the internal power supply When unplugged the Internal Supply Voltage will indicate the battery voltage Tools Database Maintenance Pressure Sensor Calibration Ther
15. ace Temp Instrument Address 0 Status Not configured Return Port Usage This is the communication method used to supply information to the instrument The possible values are Modbus Master Modbus Host Port Baud Rate This is the speed of communications which can range between 1200 and 115200 Probe Temp mV Instrument This is the make and model of the device that will be supplying the instrument with information on probe temperature probe millivolts and COF PF Possible choices are SSi AC20 SSI 9200 9205 Loop 1 Yokogawa UDP750 Honeywell UDC3300 Dualpro Loop 1 Modbus Dualpro Loop 2 Modbus Probe Temp mV Instrument Address This is the address of the atmosphere controller It can be directly entered using the numeric keypad on the touch screen Furnace Temp Instrument This is the make and model of the device that will be supplying the instrument with information on furnace temperature If there is no instrument associated with this input the probe temperature will be used Possible selections are Super Systems Inc Page 21 of 33 PGA3510 Operations Manual SSi AC20 SSI 9200 9205 Loop 1 SSI 9200 9205 Loop 2 SSI 9200 9205 Loop 3 SSI 9100 Loop 1 Yokogawa UDP750 Honeywell UDC3300 Dualpro Loop 1 Modbus Dualpro Loop 2 Modbus Furnace Temp Instrument Address This is the address of the furnace temperature instrument It can be directly entered using the numeric keypad on the touch screen Port Setup This page I
16. cted to be The same items should be checked as described above This message could indicate an issue with the sensor Regardless of the status of each of the gases the instrument can be calibrated by waiting for the readings to stabilize and pressing Start Calibration Timers will begin to count down and when they reach zero the Actual values should be the same as the Target values allowing for slight variations as a result of gas fluctuations Super Systems Inc Page 16 of 33 PGA3510 Operations Manual Use of a CO Scrubber for Zero Calibrations If an appropriate Zero calibration gas is not available the included CO Scrubber can be used The scrubber is designed to remove CO from ambient air Ambient air should not have a significant amount of CO or CH However it does have some CO In it Using the scrubber will result in the instrument measuring a gas with no CO CO or CH which is the function of a good zero gas Unfortunately depending on the environment where the calibration is being performed ambient air may contain trace amounts of CO and or CH Also the scrubber uses an expendable media that loses its effectiveness after repeated uses For these reasons Super Systems Inc recommends the use of Nitrogen or Argon instead of the scrubber whenever possible To use the CO scrubber Remove the protective caps from the scrubber and attach it to the inlet hose on the PGA3510 The pump should then be turned on This will pull ambi
17. den uen ee aa sa ele Meni Ss Sd ete aia nerd eee en hates es 10 Caron Calculat ON eesti cts ce coy ne cere dede en est Da cine lat ee RO cn ee ee 12 Nitro I AG UG OA A seul eck aecudiactianeswesaesaee sates oes EA 12 TOS SONS oe ec cate act a a dt ee dd 13 PUMP OU OL o 15 Sensor CAUDCAUON issus ss eaaa eieiei 15 Periorming azero Car MOM A AE AS A REA 16 Useofa COs Scrubber TOP Lera UDINE ds 17 FPCLORMINGsa opan CUD PallOM ESS a ent 17 Calibrating UNE OXYGEN Sensor mirta daban 17 Automatic am pude ara Metas in 18 COFPPAdusinentincrementes delle diia 19 COP PE Adjustment Interval minutes nta di 19 Minimum CO PF Val a a ra in ce inde a nement Pan 19 MANU CORRA o nde A a neo 19 CORP PEAdUSsiment Mod Rd ie ltt Nan ol 19 Communications and SOUlr GE gt Sup a a da o ae 20 ME PN CROSS O ete E de tte D Nan nt Te ii 20 er A A a Dia cas 21 Porto A rn eo ee eee ne 22 STUD a o A ER nd on 23 Calculation PAGIORS en a iaa 23 A A TS ce ee 23 SECU ENG tic teat annuity atau sige toria ios 24 Factory Default Sens ias 24 OMS SAIT ar nn and p a it re oo li 24 Language DES SN ei te 24 E o gu on ete tea eme Dino te CO mnt 24 Edie o SRE SR cates ain hele tomas at tei Man ane ht Dette 24 Calibration Dates costo ee me de 24 Power Stats a mere aleznc eae Gorn hi da tatadteceu tear ete dei 25 OO da O em ie ee eee 25 Database Malntenan te tdci D Re de Sancti t heeds 25 Pressure Sensor Gaul Dial lOM scarico dias 26 TRermuister CaliDrati ti 26 PETE IE aa
18. e effects of each variable on the calculated percent carbon The data on this screen is independent of any values that are determined by the PGA3510 and it is only provided as a reference tool User Manual An electronic version of the User Manual is located within the instrument for ease of reference Set User Cal Load User Cal This feature allows the user to create new factory default calibration settings for the sensor Instead of reverting to the factory calibration values it can revert back to different calibration settings This is accomplished by first setting the user calibration values At any time after they are set they can be restored by selecting Load User Cal Calibration Log The calibration log is not used on the PGA3510 If this option is selected a screen that reads Not valid for PGA will appear Analog Input Calibration The True Temp PGA3510 is equipped with an analog input card that is calibrated at the factory before the True Temp unit is shipped Optionally you can verify the calibration or re calibrate the unit at a later time if desired The Analog Input Calibration includes Zero and Span calibrations for millivolt input and calibration of the actual thermocouple inputs based on the type of thermocouple wire used the PGA3510 supports calibration with type K and type S wire This section provides more information on performing those calibrations if you wish to perform them Note the warning below
19. ed that the instrument be turned on for three hours prior to performing an H calibration Performing a Zero Calibration From the Sensor Calibration screen be sure that the button at the upper left of the instrument is selecting Zero Calibration and not Span Calibration When this is selected the target values will automatically go to zero Begin the flow of gas at the appropriate rate and allow the readings to come to equilibrium This occurs when the actual values are not moving in a specific direction and they display only slight movements up and down This should take approximately 45 seconds There is a column showing the Status of each gas In this area the instrument is making a comparison between the Target value and the Actual value and providing feedback based on the amount of difference between the two There are three possible words that can appear in this area OK The gas is within 10 of where it is expected to be OK The gas is between 10 and 20 of where it is expected to be This could indicate an issue with the calibration gas so the calibration gas and the associated tubing should be checked and verified to be free from leaks or improper gas composition This message does not necessarily indicate that there is a problem with the sensor or the calibration It is meant only to have the operator make sure that the proper procedures are being followed BAD The gas is more than 20 from where it is expe
20. een deleted from the screen Super Systems Inc Page 25 of 33 PGA3510 Operations Manual Maintain Users The names of all potential users can be entered here Names can be added and deleted as required Compact Database Periodic database compaction will help make data storage more efficient and allow more data to be stored before it is automatically deleted Nothing is deleted or lost when this button is pressed and the only result will be a performance improvement Pressure Sensor Calibration The pressure it set at Super Systems for local conditions For optimal performance the ambient pressure should be reset at the final destination This can be done by determining the barometric pressure and the elevation and entering them on this screen After the two values have been entered press the Calibrate button and the pressure sensor calibration will be complete Thermister Calibration This will be set at Super Systems and should not need to be adjusted by the end user It allows for the Sample gas temperature and the ambient temperature Inside the instrument to be set This should only be performed after the instrument has been powered on long enough for it to achieve temperature equilibrium SuperCalc SuperCalc is a proprietary software tool developed by SSI to allow the user to perform different scenarios and view the resulting percent carbon It allows the user to enter gas percentages probe information and temperatures to see th
21. ent air through the scrubber and into the analyzer Always replace the caps on the CO scrubber after use If it is left exposed to ambient air the media will lose its effectiveness The amount of time that the Scrubber is exposed to ambient air is directly related to its effective life span If the protective caps are replaced after each use the scrubber will provide years of service Never mistake the scrubber for a particulate filter Not only is it not designed for this purpose but because it removes the CO from the gas it will result in very inaccurate readings For these reasons it should never be used during a Span calibration Performing a Span Calibration A Span calibration is performed the similarly to the zero calibration but with two small changes First the selector button at the top should be on Span Calibration instead of Zero Calibration Second the gas values for the specific cylinder of gas being used need to be entered into the Target values To do this press the blue box associated with each gas and enter the value shown on the cylinder For example the nominal value for CO may be 20 but your cylinder may actually have 19 96 CO 19 96 is the value that should be entered as a Target After the gas values have been entered proceed with the calibration in the same manner as with the zero calibration Never perform a span calibration without first doing a zero calibration Calibrating the Oxygen Sensor The PGA3510
22. er should be lowered and to decrease the computed percent carbon it should be increased CH Factor This factor increases or decreases the significance of CH in the calculation of carbon CH does not have a significant impact on the computed percent carbon so it has a minor role in the equation If the measured gas has over 5 CH its role in the equation becomes greater than it should be In these cases the CH factor should be reduced In cases where the CH Is present in excess of 7 or 8 this factor can be reduced to zero General Setup This screen shows the current time and date for the instrument as well as the temperature scale The temperature mode can be changed from this screen but the time cannot be changed unless the PGA software is closed This can be done through the following steps Manually Setting the Time 1 Contact SSI to obtain the access code that is specific for the date and time shown on the instrument 2 Login using that access code 3 Select Factory Use Only from the bottom of the menu list Super Systems Inc Page 23 of 33 PGA3510 Operations Manual 4 Select Shut Down Software followed by Yes 9 The program will shut down and a Windows CE screen will appear 6 Click the time in the lower right corner press the stylus in this corner if the time does not automatically appear 7 Set the time and date to the desired settings 8 Select OK 9 Double click on the SaveReg
23. eturn To see the full range of options available the user must use the Configuration Pass Code Default 2 This provides the user with all available options including calibration and setup functions 1 17 2014 1 20 54 PM Carbon Calculation Nitrider Calculation Sessions Pump Control Sensor Calibration Automatic Sampling Parameters Communications and Source Setup Instrument Setup Instrument Information Tools Detail Return Super Systems Inc Page 11 of 33 PGA3510 Operations Manual To access any items on the menu list touch the item to highlight it and then press Detail A specific description of each item on the list follows Carbon Calculation Please see the Carbon Calculation section starting on page 7 Nitrider Calculation The PGA3510 has the ability to provide a calculation of values essential in nitriding and ferritic nitrocarburizing FNC processes specifically nitriding potential Ky and carburizing potential Ke To access these values open the Nitrider Calculation page Nitrider Calculation Furnace Temperature 1020 F H 38 5 Measured CO 5 00 N2 Flow 750 Measured CO2 0 100 NH3 Flow 750 Measured CH4 0 00 DA Flow 0 C gas analyzer 2 55 CO2 Flow 10 Kn 2 04 Kc 0 50 Pump Of SESSION NOT ENABLED COMMS N A O2 GAS 90 F INST 85 F COF PF ADJUST N A 0 0 Chart Return The Nitrider Calculation page displays data on current atmosphere parameters such as tempe
24. flow values and displays the calculated Ke value on the Nitrider Calculation page Sessions The instrument is logging data any time that it is powered on Data of interest can be viewed by entering its date and time Users can apply custom tags to sections of data allowing for easy Identification of viewing and recalling data These tags can include the name of the operator and the name of the equipment that is being measured The instrument has default values for each of these variables However it is highly recommended that the selections be modified so that data may be tagged in a way that is easily recognized For more information on how to set up these selections with custom entries see the Tools Database Maintenance section of this manual Operator Return Using the pull down menus select the Operator Name and Equipment Name from the list of available selections Then begin the session by pressing Start After confirming the beginning of a session a sessions Summary screen will be displayed To end the session press the red End button Super Systems Inc Page 13 of 33 PGA3510 Operations Manual 197201 ot 0 PM 1586 6 Lindberg Detail This screen will identify sessions within the date range specified at the top of the screen As a default sessions from the past 24 hours are shown By expanding the data range additional sessions can be seen These sessions are sorted with the newest entry at the top but they
25. luded with the Series 9010 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 either the operator interface keyboard and typing or using the Signature mode and writing the note with the stylus Super Systems Inc Page 9 of 33 PGA3510 Operations Manual 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 La from the chart screen 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 Menu Lists Accessing the menu screen will show four available options 1 20 2014 4 11 22 PM Carbon Calculation Nitrider Calculation Sessions Instrument Information Login Detail Return Carbon Calculation Nitrider Calculation Sessions and Instrument Information can be accessed by any users Additional menu items are available when an authorized user logs in using an appropriate Pass Code When the Supervisor Pass Code is entered default 1 the user will also be able to access the Pump Control screen Super Systems Inc Page 10 of 33 PGA3510 Operations Manual 1 17 2014 1 26 26 PM Carbon Calculation Nitrider Calculation Instrument Information Detail R
26. mistor Calibration SuperCalc User Manual Set User Cal Load User Cal Calibration Log Analog Input Calibration Valve Setup Return Database Maintenance To make the information recorded during a Session more valuable the Sessions database should be populated with relevant information regarding the people who will be using the instrument and the equipment that they will be working on Taking the time to enter this information will provide additional fields to sort by after the data has been collected in a session Maintain Equipment Types Many of the common types of heat treating equipment have been added into the PGA3510 as default entries This screen allows Irrelevant items to be removed and additional items to be added Maintain Equipment Each organization has different names for the various pieces of equipment in their shop Those names should be entered here Each name needs to be associated with a specific Equipment Type so that database should be populated first Maintain Sessions The PGA3510 is designed to delete the oldest files first in the event that the storage capacity has been exceeded It is also possible to delete old files manually by entering a date on this screen All files that were made before that date would be permanently deleted It is important to note that after the data has been downloaded to a computer a copy is stored on that computer The data will always be available on the computer even if it has b
27. n on the touch screen 11 Configure the millivolt sourcing device to deliver the desired voltage at the high end of the desired span Super Systems Inc Page 27 of 33 PGA3510 Operations Manual 12 Wait for the Current Value displayed on the screen to get as close as possible to the voltage being delivered by the millivolt sourcing device 13 Tap Calibrate Tap Yes when asked if you want to proceed with the calibration A progress indicator will appear Select Input AS O Zero Span rr rr Suggested Target 1000 0 Current Value1005 0 mV Idle Calibrate Return 14 When the process completes Span calibration is finished To perform a temperature calibration Cold Junction Trim Needed Thermocouple wire type S and or K temperature sourcing device 1 Openthe Analog Input Calibration page 2 Make sure that the selected input at the top of the screen is T C K or T C S depending on which thermocouple wire type you are using Super Systems Inc Page 28 of 33 PGA3510 Operations Manual Select Input TICS Cold Junction Trim Supplied temperature 1700 0 Current Value1698 3 Idle Calibrate Return 3 Prepare the temperature sourcing device This device should be capable of sourcing a temperature from type S and type K thermocouple types 4 Connect the thermocouple wire from the temperature sourcing device to the appropriate Input on
28. nt is capable of communicating directly with a control instrument This is valuable because it will provide real time entry of the temperature and millivolt information from the probe allowing for an accurate comparison between the IR Carbon and the Probe Carbon To establish this communications link see Communications and Source Setup Atmosphere Temp Sources The Automatic Sampling Parameters screen will allow the user to adjust the way that the PGA3510 updates the COF PF in the atmosphere controller All of the parameters on this page can be disregarded if the COF PF Adjustment Mode is set to Monitor mode These parameters only apply when the instrument is in Control mode Super Systems Inc Page 18 of 33 PGA3510 Operations Manual Automatic Sampling Parameters COF PF Adjustment Increment 1 COF PF Adjustment Interval minutes 1 Minimum COF PF Value 130 Maximum COF PF Value 220 COF PF Adjustment Mode Monitor Return COF PF Adjustment Increment When adjustments are made automatically this value indicates the size of the step that is made when the COF PF is changed It is recommended that this number remain low to avoid making sudden changes to the process that could be caused by temporary conditions COF PF Adjustment Interval minutes This indicates the frequency that automatic adjustments are made We recommend making small changes at a frequent interval instead of making large changes at longer intervals Thi
29. r 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
30. rature and measured values for CO C02 CH4 02 and H2 if the H2 sensor is installed The calculated value for C is also shown User provided flow values for N NH DA and CO are used by the PGA3510 in performing calculations The flow values are visible on the right side of the Nitrider Calculation page To change a flow value simply tap on the blue field for that value Anumeric entry page will appear allowing you to change the value For the purpose of Ky and K calculations any valid gas flow unit for example cubic feet per minute or cfm may be used The flow unit must be the same for all gases NOTE If one or more of the flow gases do not show up in the list it is likely that the gas flow valve is not enabled in the Tools gt Valve Setup menu Refer to the Valve Setup section on page 27 for more information K provides a measurement of the amount of nitrogen that can be diffused into a metal e g iron it is a derived measurement based on the partial pressures of NH and H The PGA3510 performs the calculation of Ky using user provided flow values and displays the calculated K value on the Nitrider Calculation page Super Systems Inc Page 12 of 33 PGA3510 Operations Manual Ke provides a measurement of the amount of carbon that can be diffused into a metal it is derived from a calculation involving the partial pressures of CO H CO and H 0 The PGA3510 performs the required calculation using user provided
31. rn Carbon Calculation The PGA3510 determines the percent carbon in the sample gas using measured amounts of CO CO and CH along with the Furnace Temperature The Furnace Temperature Is either entered by the user or obtained automatically from the Furnace Temperature Controller via RS 485 communications Additionally the carbon percentage measured by the PGA3510 can be used as a comparison to the carbon percentage measured by a furnace s oxygen probe This is accomplished either by manually entering the Probe Temperature Probe Millivolts and the Probe CO Factor into the PGA3510 or by obtaining the information automatically via RS 485 communications to the Furnace Carbon Controller Providing the probe information allows the PGA3510 to suggest an adjustment for the probe CO Factor or Process Factor in order to keep the oxygen probe measuring properly Super Systems Inc Page 7 of 33 PGA3510 Operations Manual EE 40221 455448912 BEE Carbon Calculation Pi Probe Temperature 1698 F 21 88 Probe Millivolts 1072 mV 0 737 C probe 1 8 55 Probe CO Factor C gas analyzer 0 27 Suggested CO SESSION IN PROGRESS COMMS N A O2 Pump Off 16 2 INTERNAL TEMP 84 F COF PF ADJUST N A Change Adjustment Factor Chart Return Using infra red analysis is considered a more accurate method for determining the percent carbon of a gas compared to using an oxygen probe alone The single point oxygen probe assumes a theoretical
32. s icon 10 Select OK from the Registry Save Complete notification 11 Turn the instrument off and wait for the screen to turn off 12 Turn the instrument back on 13 The instrument will automatically boot up as a gas analyzer with the IP address that has been manually entered Security Settings This page is used to change the pass code used for logging into the menu list The default setting for the Supervisor Pass Code Is 1 and the default setting for Configuration is 2 The maximum value for either code Is 32767 The Configuration Code will also work for all items on the Supervisor Pass Code items so entering the Configuration Code default 2 will provide access to all available menus Factory Default Settings Selecting this option will cause the instrument to revert back to the settings that it contained when it came from Super Systems Any changes or modifications made since then will be lost Other Settings This screen displays calculated dew point This value is not normally displayed because it is only accurate during certain conditions Calculating dew point by using the gas values requires assumptions to be made regarding the composition of the gas being sampled Since these assumptions are not always accurate the resulting dew point is not always accurate When using Endothermic gas In a heat treating environment the calculated dew point will usually be close to the correct value but there is no substitute for
33. s should be included with the PGA 1 Portable Gas Analyzer Bowl Filter Sample Tubing In Line Filter Notepad Touch Screen Stylus XGA Viewer Software CD USB Cable CO Scrubber 0 Power Cord 1 Product Manual ee a eae ee Super Systems Inc Page 5 of 33 PGA3510 Operations Manual Basic Operating Description The Model PGA3510 has been designed for the simultaneous analysis of CO CO and CH in heat treat furnace atmosphere gases It uses a color touch screen display operator interface for data entry and for viewing Selections can be made on the screen using a finger or a stylus Avoid the use of sharp objects pens paperclips screw drivers etc as they can cause permanent damage to the screen and void the warranty of the instrument After the power switch is turned on it will take approximately 30 seconds for the PGA3510 software to automatically load Once the software is properly loaded the instrument is ready to use When the power switch is turned off the PGA3510 initiates a controlled shutdown procedure which takes about 15 seconds Following the controlled shutdown the instrument will completely turn off Hydrogen Cell Note For highest H accuracy it is recommended that the instrument be powered on for 60 minutes before measurements are taken Default Screen Once the PGA3510 has successfully loaded its software the default screen will be displayed A SSi PGA3510 CO 19 56 D CO 0 446 13 L CH 5
34. s used to set the parameters for the communications ports The factory default settings are shown below and they should not need to be changed by the operator Communications Setup Port Setup Host Address RS232 Port A Baud Rate RS232 Port A Mode RS485 Port C Baud Rate RS485 Port C Mode RS485 Port D Baud Rate RS485 Port D Mode Super Systems Inc 1 19200 Modbus Master 19200 Modbus 19200 Modbus Master Return Page 22 of 33 PGA3510 Operations Manual Instrument Setup The items shown in this menu list are settings that should only need to be changed once Any modifications to the default values will be saved in the instrument Instrument Setup Calculation Factors General Setup Security Settings Factory Default Settings Other Settings Language Setup Return Calculation Factors There are two items that will influence the calculation of carbon the IR Shim Factor and the CH Factor These values should only be changed after determining that additional adjustments are required based on the specific conditions and equipment at each facility Neither of these items should be modified without significant testing or consultation from Super Systems Inc IR Shim Factor Changing the IR Shim Factor is a way of modifying the computed percent carbon The nominal value is 180 There is an inverse relationship between the IR Shim Factor and computed percent carbon To increase the computed percent carbon this numb
35. s will prevent temporary changes in atmosphere from making dramatic adjustments to the COF PF Minimum COF PF Value As a safeguard the COF PF can be prevented from dropping below a certain point This point is the Minimum COF PF value Maximum COF PF Value The Maximum COF PF can also be entered as a safeguard COF PF Adjustment Mode This selection determines if changes to the COF PF will be made automatically or if the instrument will monitor the conditions without making any changes When in Monitor mode a COF PF will continue to be suggested but no modifications will be made to the atmosphere controller Super Systems Inc Page 19 of 33 PGA3510 Operations Manual Communications and Source Setup This screen allows the user to view and modify the method of communications between the instrument and external devices Communications and Source Setup IP Address Atmosphere Temp Sources Port Setup Detail Return IP Address This section identifies the IP Address of the instrument When connected to a network the PGA3510 S V a S creen will obtain its own IP Address It does this during the power up procedure so if communication la Ethernet is preferred plug the cable into the instrument before turning it on To use a specific IP ddress it must be entered on the Windows CE screen This can only be accessed when the Gas Analyzer oftware has been shut down Manually Setting the IP Address S Contact SS
36. uses an electrochemical oxygen sensor that should last approximately two years depending on usage It measures oxygen to a resolution of 0 1 so it is not suitable for calculating carbon ina furnace Its intended use is for troubleshooting problems such as air and or water leaks The information from this sensor Is not used in the calculation of percent carbon Calibration of the Oxygen sensor does not require a special calibration gas Ambient air contains 20 9 02 and since that concentration Is relatively stable it can be used to perform a span calibration on the sensor There is no drift at the low range of the sensor so there is no Zero Calibration function for the Oxygen sensor There is only a Span Calibration To perform a Span calibration Take the instrument to an office or outdoors where it will be in fresh air Press the Calibrate 02 button on the Sensor Calibration screen When the Oxygen Calibration screen is entered the pump automatically turns on When the Actual value stabilizes press the Start Calibration button This will make the Actual value match the Target value Super Systems Inc Page 17 of 33 PGA3510 Operations Manual Hel 40221 5292825694 Oxygen Sensor Calibration Gas Target Actual Oxygen e 1 Last Oxygen calibration 1 1 1980 10 days 20 hours 12 minutes Span calibration to be performed with fresh ambient air using the pump Start Calibration Automatic Sampling Parameters This instrume
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