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CGA351 Operating Manual 2 MB

1. ccA351 19 00 483 CGA 351 User s Manual 107 Appendix C Optional Enclosures TB1 OUTPUTS TB2 INPUTS NOTE For proper operation the unit must be powered by the voltage specified at the RS232 Transmit TX Brown Sensor 1 White time of purchase RS232 Receive RX Red j Sensor 2 White RS232 Return RTN Orange Any Gnd Shield N A TB3 POWER Any Shield or Ground Yellow Thermocouple N A Yellow Description Color Analog Output SIG Green Te Thermocouple N A Red L Line Black Analog Output SIG Blue ALL Any Gnd Shield G White N Neutral White Normally Open Standard Mode Violet Furnace 5 White Ground unit to protective an ALARM 1 Common Gray pisa Furnace 6 White earth post provided Normally Closed Failsafe Mode White 90 265 VAC 50 60 Hz 900 W Normally Open Standard Mode Black ALARM 2 Common White Red Normally Closed Failsafe Mode White Red Description Wire Color Pin Description Wire Color e9eeeoooooooo 00000000 500 ARARAARAARA P 1 2 C G NO C NC NO C NC G G 1 2 L N G COMM 4 20mA ALARM 1 ALARM 2 O2 TC HEATER 90 265 VAC T 3 Figure 17 CGA 351 Rack Mount Versi
2. Trip Baud Rate Node ID Comm Reset Data Length Fail Safe Non Fail Safe Parity Fail Safe Stop Bits Comm Type Setpoint Temp Control Auto Range Num_of_Auto_Ranges PCNT Table PPM Table Air Offset Prop Band Load Slot Load Main Erase Slot Erase Main Lock Menus Int Time Max Duty Cycle Default Line Voltage Heater ppm Lock All Versions 1 Param Units1 CGA 351 Menu Map Figure 8 pont Security Level Key Sequence 1 Param Units2 Unlocked ESC Impedance Operator Locked ESC ENT ESC General Locked ESC ENT ESC as selected in 1 Cfg menu Factory Locked ESC ENT ESC View Temp Controls CGA 351 User s Manual 25 Chapter 3
3. Note The 0 2V option is software selected and therefore there is no need for hardware modifications to output 0 2 volts DC The Namur option is also available in the above list box The Namur NE43 specification requires a 4 20 mA output to be clamped in specific bands to indicate out of range errors The 0 2V option is software selected and therefore there is no need for hardware modifications to output 0 2 volts DC The meter now automatically returns to the Analog Output prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the analog output CGA 351 User s Manual 49 Chapter 4 Setup and Calibration 4 9 2 Setting the Zero Setpoint Enter the analog output setup menu and proceed as follows User Aout Use the A and Y keys to select Zero Setpoint and Aout Type ENTER Zero Setpoint p Span Setpoint POWER ESC ENTER Note The Test Zero Trim and Span Trim options are also available in the above list box At the next prompt enter the desired zero setpoint User Aout Zero Set Use 4 and gt to position the cursor under the desired character Then use A and 0000 00 V to increment the value p Press ENTER when done POWER ESC ENTER The meter now automatically returns to the Analog Output prompt Either
4. A list of the available unit types is shown Use the A and W keys to select the desired units parts per million or percent and press ENTER If either of the Temperature inputs is selected for display C and F are available as the unit types For the Sensor and Duty Cycle inputs mV and pent respectively are the only available unit types Note 0 Display 0 Fault Alarm From 1 Cfg Ox pent Add Remove OQ Cancel POWER ESC ENTER above list box A list of the available output devices is shown Follow the instructions below to select the desired outputs The 0 Analog Output 2 Alarm 1 2 Alarm 2 2 Alarm 3 and 2 Alarm 4 options are also available in the To select the desired output s from the previous list box complete the following steps 1 Use the A and V keys to highlight a specific output For this example make sure that 0 Display is selected as one of the outputs Use the 4 and gt keys to select Add or Remove and press the ENTER key to change the status of the selected output An output is selected if an asterisk appears to its left When all of the desired outputs have been selected use the 4 and gt keys to select OK and press ENTER 1 Oxygen 2 71 ppm POWER ESC ENTER Press ESC four times to return the display to t
5. 800 900 1000 TEMPERATURE C Figure 9 TC Voltage vs Temperature Table 6 TC Voltage vs Temperature 0 7981 29 5841 19 8462 30 0002 21 9783 30 4153 24 1073 30 8296 24 5322 31 2429 24 9566 31 6553 25 3805 32 0668 25 8039 32 4773 26 2267 34 5150 26 6489 36 5278 27 0705 38 5154 27 4914 40 4775 27 9115 42 4131 28 3309 44 3206 28 7494 46 1973 29 1672 48 0401 CGA 351 User s Manual Chapter 5 Service and Maintenance 5 2 3 Checking the Oxygen Sensor If the thermocouple voltage was within the normal range the troubleshooting sequence should continue here Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 1 Disconnect the oxygen sensor O2 leads white 7 from terminal block TB2 2 Using a digital multimeter measure the resistance between the two disconnected oxygen sensor leads 3 Ifthe measurement indicates an open loop OL adjust the clips to make certain they are making good contact with the oxygen sensor and take another reading If an open loop is still measured the oxygen sensor is defective and must be replaced Note A cold sensor will always indicate an open loop OL If the oxygen sensor tests good proceed to the next section to continue the troubleshooting procedure 5 2 4 Checking the Sensor Furnace If the sensor furnace operating temperature was too low the troubl
6. POWER ESC ENTER Slct Cal Menu Item POWER ESC ENTER POWER ESC ENTER 28 Use the A and W keys to select 2 Cal and press ENTER Use the A and Y keys to select Setup and press ENTER Use the A and W keys to select Alarms and press ENTER CGA 351 User s Manual Chapter 4 Setup and Calibration 44 Setting Up the Alarm Relays cont Alarms Use the A and W keys to select Alarm 1 and press ENTER Alarm 2 Alarm 3 POWER ESC ENTER Note The Alarm 4 option is also available in the above list box The following alarm features may be set in this submenu Trip Type specifies whether the alarm relay triggers when the live measurement value moves above or below the trip value Trip Value specifies the live measurement value at which the alarm relay triggers e Deadband Value specifies a small range of live measurement values centered on the trip value for which the alarm relay does not trigger or reset This prevents the alarm relay from repeatedly triggering and resetting when the live measurement value is very close to the trip value e Test permits the manual triggering and resetting of the alarm relay to verify that it is working properly e Fail Safe specifies whether the alarm relay is energized during normal operation or during an error condition Go to the appropriate sub section to set the desire
7. Temp Cn Air Offset Using the 4 and P keys position the cursor under the desired character Then use 0000 00 the A and W keys to P increment the value When done press ENTER POWER ESC ENTER Tem Unit Measuring This message indicates that changes in this menu will alter the live data output To accept the new value use the 4 and Yes No Cancel gt keys to select Yes and press ENTER Unit measuring Accept changes POWER ESC ENTER The meter now automatically returns to the Temp Control prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the temperature control 38 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 5 4 Selecting the Gas Type CAUTION Improper temperature controls settings can seriously degrade the performance of the instrument Never change these settings without specific instructions from GE Enter the temperature control menu and proceed as follows Temp Cntrl Use the A and Y keys to Air Offset select Select Gas Type and ENTER Select Gas Type preset l Prop Band POWER ESC ENTER Note The Setpoint Sensor Temp Int Time Max Duty Cycle and Default options are also available in the above list box Te Select
8. All environmental and installation factors should have been discussed with a GE application engineer or field sales person at the time the CGA 351 was ordered Thus the equipment should be suited to the application and the planned installation site Before installing the unit however read the following guidelines to verify that the best installation site has been chosen for optimum instrument accuracy and reliability Make sure that The CGA 351 enclosures are suitable for the environmental conditions at the installation site The analyzer system will be installed in a location with little or no vibration The ambient temperature at the installation site is between 25 and 50 C 13 and 122 P There are no restrictions in the discharge line i e flow control valves downstream of the meter The CGA 351 system is installed in a location that provides ready access for programming testing and servicing the unit The cables will be protected from excessive physical strain bending pulling twisting etc Do not subject the cables to temperatures above 65 C 149 F or below 50 C 58 F e The line voltage used at the planned installation site corresponds to the factory preset line voltage rating for the meter CGA 351 User s Manual 7 Chapter 2 Installation 2 3 Mounting the CGA 351 This section explains how to mount the analyzer components at the installation site and how to connect the sample syst
9. Enter the alarm setup menu and proceed as follows Alarms Alarm Feat Use the A and Y keys to Deadband Value select Fail Safe and press ENTER Test POWER ESC ENTER Note The Trip Type and Trip Value options are also available in the above list box At the next prompt enter the desired operating mode Note In fail safe mode the alarm relay is constantly energized during normal operation and is de energized when the trip point is crossed In normal non fail safe operation the alarm relay is energized only when the trip point is crossed Alarms Fail Safe Use the A and W keys to Non Fail Safe select the desired operating mode and press ENTER Fail Safe POWER ESC ENTER The meter now automatically returns to the Alarm Features prompt Press ESC until you exit the User Program 34 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 5 Setting the Temperature Controls To configure the temperature control circuits of the CGA 351 complete the following instructions CAUTION Improper temperature controls settings can seriously degrade the performance of the instrument Never change these settings without specific instructions from GE Use the A and W keys to select 1 Cal and press ENTER POWER ESC ENTER Cal Diag Use the 4 and
10. If a faulty component is discovered in the CGA 351 that component is usually replaceable on site Contact GE to obtain a new part and proceed to the appropriate section of this chapter for installation instructions WARNING To ensure safe operation of the CGA 351 it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations for installing electrical equipment In addition all procedures should be performed by trained service personnel 5 2 General Troubleshooting This section discusses the following general categories of problems that may arise with the CGA 351 e Faulty wiring e A faulty thermocouple e A faulty oxygen sensor e A faulty sensor furnace Missing sensor furnace voltage Use this section to troubleshoot any malfunction in the CGA 351 Refer to Figure 10 on page 89 and complete the following sections in the sequence indicated Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C CGA 351 User s Manual 69 Chapter 5 Service and Maintenance 5 2 1 Checking the Wiring Complete the two checks listed below to correct any wiring problems WARNING Be careful when tightening the terminal block electrical connections Full line voltage is present on some terminals WARNING These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively
11. R gas constant 8 31441 volt coulomb mole K n electrons transferred per molecule 4 mole In natural logarithm 2 303 log p p O partial pressure on reference gas side 0 2093 p O partial pressure on sample gas side Ej voltage on reference face with respect to the sample face CGA 351 User s Manual 95 Appendix A The Nernst Equation A 3 The CGA 351 Nernst Equation The Nernst Equation specifically applicable to the CGA 351 analyzer is obtained by substituting the above values into the general equation converting the natural logarithm to the common logarithm base 10 and converting the units for E 5 to millivolts This results in the following equation E mV 0 049605 e T log E P2 The CGA 351 measures the temperature of the oxygen sensor and automatically inserts the correct value into the Nernst Equation For example at the standard oxygen sensor operating temperature of 700 C the above equation becomes E mV 48273 e 1og 222 P2 The voltage drop across the zirconium oxide sensor as calculated from the Nernst equation is then sent to the linearizer circuit The circuit produces a linear analog output that represents the percentage of oxygen in the sample gas and this signal is available for display on the digital panel meter and or for output to an external device For convenience the standard Nernst equation for the CGA 351 zirconium oxide oxygen analyzer shown above has b
12. 61 W Warm Up Ties cesa ces es Cea gs des 15 16 WIN cu ete ex sup is 115 Wiring See Part Name CGA 351 User s Manual Index 113 Index no content intended for this page 114 CGA 351 User s Manual Warranty Warranty Each instrument manufactured by GE Sensing is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument at the sole discretion of GE Sensing Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Sensing determines that the equipment was defective the warranty period is one year from delivery for electronic or mechanical failures one year from delivery for sensor shelf life If GE Sensing determines that the equipment was damaged by misuse improper installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Sensing the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied including warranties or merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade Return Policy If a GE Sensing instrument malfunctions within the warranty period the followin
13. A AN 1 Open the cover on the sensor enclosure and remove the lower front panel from the electronics enclosure Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 2 Check all wiring including that performed at the factory Refer to the wiring instructions in Chapter 2 Installation and the wiring diagram in Figure 6 on page 14 to make sure that all wires are attached to the correct pins If any connections are loose turn the screws clockwise with a small screwdriver to secure the connections 3 Locate the oxygen sensor clips see Figure 10 on page 89 and short them together with a jumper The oxygen display should read 20 93 Note Due to an uncorrected offset in some units an exact reading of 20 93 may not be obtained However the result should be close to this value 4 If the wiring is good and a 20 93 oxygen reading is obtained with the shorted clips remove the jumper and proceed to the next section Note If an open loop OL is measured at the oxygen sensor clips recheck the wiring and try again If the OL reading repeats contact ge for assistance Note A cold sensor will always indicate an open loop OL 70 CGA 351 User s Manual Chapter 5 Service and Maintenance 5 2 2 Checking the Thermocouple To check the thermocouple temperature sensor used in the CGA 351 complete the following steps WARNING There are very hot surfaces in the se
14. Be careful when using Erase Slot or Erase Main to make sure the information is no longer needed At the following prompt an option card may be added or removed in an expansion slot or options may be added or removed in the main slot 0 position Setup Load Slot Load Main Erase Slot POWER ESC ENTER Use the A and Y keys to select the desired action and press ENTER Note The Erase Main option is also available in the above list box Setup Load Slot 2 Load POWER ESC ENTER ID Size Received Block Write to Slot 1 POWER ESC ENTER Use the A and Y keys to select the desired slot designation and press ENTER Using a personal computer enter the appropriate information This completes the setting up of the option card slot To exit the User Program disconnect and reconnect power to system Follow the same procedure to add or remove additional option cards 60 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 13 2 Setting the Security Levels To set up the menu security levels enter the User Program and proceed as follows Cfg Cal Disp Use the 4 and gt keys to select Opt and press ENTER POWER ESC ENTER Use the A and Y keys to select the desired option
15. Pl mbing sri eese eS ge x ue eade 15 17 Line Power Winter satel Gam ades eos MEA 12 LVD Compliance s ues eoe ARS E ss 7 16 99 M Menus Locking ro Lr avi equ se fends EY Pa ead 61 N Needle Valves AS wart egest VENUS e Ent AE eras 2 Nernst Equation DOSCFIB GIG 2 05 9 dE cosa ura ned E RARIOR 95 Graphical Form rs el hy pe 96 Numeric Poma veal ake 95 Node Tio eno ELA da Di A RR Tn us A LI 57 O Option Card Slots Setting Up o 59 Option Card Replacing oooooooooo o 87 Ordering Informati0N oooooooo o 93 Ory Gen BITOLS ub a est ec mend uet d v dE 74 Oxygen Sensor See Sensor P Parity Saco Dui ena Gea eae a ana Ge 58 PID Heater Control seo lo E eu 6 Plumbing L aks 5 2 pk as 15 14 Power Requirements 97 Powering Uns ec Ray Rer ERSTER 16 Proportional Band a y ves S ex x ws 6 40 R Rack Mount Version 00e eee ee eee 101 112 Range COUIDUIS ure pP eu qat NU etre Qo BA a 92 Percent Oxyoen cto dvo v POS VADE 92 Recovery Mme ee s ht Pb IO SR qud 78 Replacing See Part Name Return Policy cere A eg tees 115 RS232 RS485 See Serial Port RTD See Thermocouple S Sample Gas Contamination 76 Sample System Mounting sisi ias 8 102 PIPING cit ias 8 102 A Bed oat ove San m eed 3 Sensor Calibration a v s yos rp UE EE TIUS Eu 62 Clips Replacing resul Ce SL ab as a 79 Description ied p REF sha ieee eae 220 Replace mides 80 TESNE Ada 73 MIS O stot
16. Zero Trim and press ENTER Note The Aout Type Zero Setpoint and Span Trim options are also available in the above list box At the next prompt enter the desired value for the zero trim User Aout Zero Trim p 0 q POWER ESC ENTER Use A and V to increment the value Press ENTER when done The meter now automatically returns to the Analog Output prompt Using the procedure in Testing the Analog Output on page 52 reset the Test Percent to its normal value Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the analog output CGA 351 User s Manual 535 Chapter 4 Setup and Calibration 4 9 6 Setting the Span Trim Using the procedure in Testing the Analog Output on page 52 set the Test Percent to 100 At the analog output setup menu proceed as follows User Aout Test Zero Trim POWER ESC ENTER Use the A and W keys to select Span Trim and press ENTER Note The Aout Type Zero Setpoint and Span Setpoint options are also available in the above list box At the next prompt enter the desired value for the span trim p 0 q User Aout Span Trim POWER ESC ENTER Use A and V to increment the value Press ENTER when done The meter
17. gt keys to select Setup and press ENTER Slct Cal Menu Item POWER ESC ENTER Use the A and W keys to Temp Control select Temp Control and press ENTER Auto Range Line Voltage POWER ESC ENTER Proceed to the appropriate sub section to program the desired temperature control feature CGA 351 User s Manual 35 Chapter 4 Setup and Calibration 4 5 1 Entering the Setpoint CAUTION Improper temperature controls settings can seriously degrade the performance of the instrument Never change these settings without specific instructions from GE Enter the temperature control menu as described there and proceed as follows Temp Cntrl Use the A and W keys to select Setpoint and press ENTER Sensor Temp Air Offset POWER ESC ENTER Note The Select Gas Type Prop Band Int Time Max Duty Cycle and Default options are also available in the above list box At the next prompt enter the desired operating temperature for the analyzer Usually this is a 700 780 C oxygen sensor temperature IMPORTANT Calibrating the meter automatically adjusts the value of the setpoint temperature Temp Cntrl Set Point Using the 4 and P keys Setpoint position the cursor under the 000 desired character Then use the A and W keys to P increment the value W
18. 2006 95 EC the CGA 351 requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit 3 4 User Program Security The CGA 351 has been equipped with a User Program see the menu map in Figure 8 on page 25 that permits the setup and calibration of the instrument for optimum performance in any specific application However to prevent accidental changes to critical system parameters four levels of security are imposed on the various submenus within the User Program These are e Unlocked access to these submenus is gained simply by pressing the ESC key No password is required e Basic locked access to these submenus is gained by pressing the ESC ENT and ESC keys in sequence Then a password must be entered The default password is 2719 e General locked access to these submenus is gained by pressing the ESC ENT and ESC keys in sequence Then a password must be entered e Advanced locked access to these submenus is gained by pressing the ESC ENT and ESC keys in sequence Then a password must be entered Note The passwords required for the three locked categories mentioned above are all different 16 CGA 351 User s Manual Chapter 3 Operation 3 5 Configuring the Digital Display The digital display panel at the top of the electronics enclosure
19. 4 Setup and Calibration 4 5 8 Restoring the Default Values To reset the Setpoint Proportional Band Integration Time and Max Duty Cycle parameters to their default values enter the temperature control menu and proceed as follows IMPORTANT Restoring the default values invalidates the existing calibration It will be necessary to recalibrate the meter see Calibrating the CGA 351 on page 62 before reliable readings are obtained From Temp Control Int Time Max Duty Cycle POWER ESC ENTER Use the A and Y keys to select Default and press ENTER Note The Setpoint Air Offset and Prop Band options are also available in the above list box Tem Unit Measuring Unit measuring Accept changes No Cancel POWER ESC ENTER This message indicates that changes in this menu will alter the live data output To accept the new value use the 4 and gt keys to select Yes and press ENTER The meter now automatically returns to the Temp Control prompt Press ESC until you exit the User Program CGA 351 User s Manual 43 Chapter 4 Setup and Calibration 4 6 Auto Range Analog Output This CGA 351 Zirconia Oxygen Analyzer has been configured with a new software version that permits the instrument to automatically select the appropriate 4 20 mA analog output range from among 1 4 predefined
20. 5F Measurement amp Control Oxygen Analysis CGA 351 Zirconium Oxide Oxygen Analyzer User s Manual Zirconia Oxygen Analyzer 910 199 Rev E imagination at work May 2013 CGA 351 Zirconium Oxide Oxygen Analyzer User s Manual 910 199 Rev E May 2013 ge mcs com 2013 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this page Preface Information Paragraphs Note paragraphs provide information that provides a deeper understanding of the situation but is not essential to the proper completion of the instructions Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance Caution paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to property or equipment e Warning paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to personnel Cautionary information is also included when applicable Safety Issues WARNING Itis the responsibility of the user to make sure all local county state and national codes regulations rules and laws related to safety and safe operating conditions are met for each installation Auxiliary Equipment Local Safety Standards
21. CGA 351 is now ready to be placed back into service 86 CGA 351 User s Manual Chapter 5 Service and Maintenance 5 5 2c Replacing the Option Card To replace a defective option card complete the following steps Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 1 Disconnect the main power to the CGA 351 WARNING Failure to cut the main power at the external disconnect device before proceeding will result in serious personal injury Remove the panel meter as described in a previous section Remove the defective option card from Slot 2 of the panel meter and install the new option card in its place Reinstall the panel meter into the electronics enclosure as described in a previous section Reconnect the main power to the analyzer Swe ow eom Refer to Chapter 3 Operation and Chapter 4 Setup and Calibration to reprogram the new digital panel meter The CGA 351 is now ready to be placed back into service 5 6 Recommended Spare Parts The recommended spare parts for the CGA 351 are listed in Table 9 below Table 9 Spare Parts List CGA 351 Part Number Description 1214 510 Outer Oxygen Sensor Clip 238 085 Thermocouple K Type Temperature Detector Assembly 705 950 Inlet Ceramic Tube Fitting platinum mesh included 705 952 Zirconium Oxide Oxygen Sensor Assembly with manifold 2271 007 Furnace 183 047 LCD Display PCB 703 1304 01 Controll
22. Duty Cycle and Default options are also available in the At the next prompt enter the desired value for the proportional band Temp Cntrl Se Prop Prop 0000 P POWER ESC ENTER Tem Unit measuring Unit measuring Accept changes Yes No Cancel POWER ESC ENTER Using the 4 and P keys position the cursor under the desired character Then use the A and W keys to increment the value When done press ENTER This message indicates that changes in this menu will alter the live data output To accept the new value use the 4 and gt keys to select Yes and press ENTER The meter now automatically returns to the Temp Control prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the temperature control 40 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 5 6 Setting the Integration Time CAUTION Improper temperature controls settings can seriously degrade the performance of the instrument Never change these settings without specific instructions from GE Enter the temperature control menu as described on page 35 and proceed as follows Note Temp Cntrl Prop Band Max Duty Cycle POWER ESC ENTER Note above list box See The Heater Control
23. Gas Type Use the A and W keys to select the type of gas When done press ENTER Oil Propane Butane POWER ESC ENTER Note The Natural Gas Coke Oven Gas Methane and Other options are also available in the above list box Tem Enter HC Ratio Using the 4 and gt keys position the cursor under the desired character Then use 0 0000 the A and V keys to p increment the value When done press ENTER POWER ESC ENTER The meter now automatically returns to the Temp Control prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the temperature control CGA 351 User s Manual 39 Chapter 4 Setup and Calibration 4 5 5 Selecting the Proportional Band CAUTION Improper temperature controls settings can seriously degrade the performance of the instrument Never change these settings without specific instructions from GE Enter the temperature control menu and proceed as follows Note Temp Cntrl Air Offset Select Gas Type Prop Band POWER ESC ENTER Note above list box See The Heater Control Circuit on page 6 for a discussion of the proportional band Use the A and Y keys to select Prop Band and press ENTER The Setpoint Sensor Temp Int Time Max
24. Operation no content intended for this page CGA 351 User s Manual 26 Chapter 4 Setup and Calibration Chapter 4 Setup and Calibration 4 1 Introduction Although the CGA 351 is set up at the factory with default operational parameter values that are suitable for many applications the User Program provides a means for customizing many of the setup parameters Proper setup of the analyzer is very important to ensure accurate data readings Generally changes in calibration result from aging of the zirconium oxide oxygen sensor Within limits oxygen reading errors can usually be compensated for by making minor temperature adjustments The zirconium oxide oxygen sensor should be calibrated once or twice a week for the first month of operation and every 2 3 months thereafter WARNING To ensure safe operation of the CGA 351 it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations for installing electrical equipment In addition all procedures should be performed by trained service personnel Follow the instructions in this chapter exactly to ensure proper setup and calibration of the CGA 351 4 2 Accessing the User Program To ensure accurate oxygen level readings and to make use of the alarm relays serial port and analog output the appropriate entries must be made in the User Program Follow the instructions in this section to accomplish th
25. PERREUE diodo 84 5 6 Recommended Spare Parts accesses eine AER FECHA TER KK EA memes ees bed ane Re As Rb etas 87 Chapter 6 Specifications 64 ENERO Specifications AA pe pe bes etin d aca Falerno rues sed Dort ance wots 91 625 Operating sbeciHE HOS cs mia cals are dai moo ieee ra arta top m Ee ud b S pe rettet id 92 Es OTHerime ALi es E ad ee EE ea nud 93 Appendix A The Nernst Equation AL NAUC N zo O oo pere ROI hs OAS HO du Mir Ga boa i pedis ipt 95 Ae TEQUE CORGIIONS cesta rd UE FERRY ties 95 A 3 The CSAS S LNSETSEEBEIGUOHS nct hus sae uie ue cts E UE 96 CGA 351 User s Manual vii Contents Appendix B CE Mark Compliance B 1 B 2 B 3 C 1 C2 C3 C 4 III TRAE AAA AER OA ae aE AEE ASA 99 GUL Tm al 6 19 6 a ARE 99 WD COW as Uia ccs dtu Lost Dp A LU 99 Appendix C Optional Enclosures ME i a e EE ae ok A 101 aere A es ee a ES ee a a E el en ee a 101 C 2 1 Mounting the Rack Mount CGA 351 sicario ET ete det ocd head CPP ROMS ees 101 C2 2 Connecting the Sample SUM data AE A at 102 C23 Wiring Tne Rack Mount CGA 351 cos A A OX ea ees 102 Rack TOME ETSI ROI ERRORI ORE rote a a oe eho ace Reet ee AB RATE Ae tts 104 Rack Mount Service and Maintenance s acoso iater a ak RS 104 a s Cs erobert OO 104 Cere REDIGCING the FISBSS oc e tp nett Soares 105 viii CGA 351 User s Manual Chapter 1 General Information Chapter 1 General Information 1 1 Introduction The CGA 35 monitors the oxygen content of any clean a
26. The user must make sure that he operates all auxiliary equipment in accordance with local codes standards regulations or laws applicable to safety Working Area WARNING Auxiliary equipment may have both manual and automatic modes of operation As equipment can move suddenly and without warning do not enter the work cell of this equipment during automatic operation and do not enter the work envelope of this equipment during manual operation If you do serious injury can result WARNING Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform maintenance procedures on the equipment Qualification of Personnel Make sure that all personnel have manufacturer approved training applicable to the auxiliary equipment Personal Safety Equipment Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment Examples include safety glasses protective headgear safety shoes etc Unauthorized Operation Make sure that unauthorized personnel cannot gain access to the operation of the equipment CGA 351 User s Manual iii Preface Environmental Compliance Waste Electrical and Electronic Equipment WEEE Directive GE Measurement amp Control Solutions is an active participant in Europe s Waste Electrical and Electronic Equipment WEEE take back initiative directive 2002 96 EC The equipment that you bought has required the extraction a
27. and gt to position the cursor under each character Use A and V to increment the value of each so the total P number is between 00 and 99 When done press ENTER 00 POWER ESC ENTER This completes the adjusting of the display backlight Either press ESC until you exit the User Program or continue programming 56 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 12 Setting Up the Serial Port To set up the serial port enter the User Program and proceed as follows Setup Lock Menus POWER ESC ENTER Use the 4 and gt keys to select Opt Then Use the A and W keys to select User and press ENTER Note The Lock All and Versions options are also available User POWER ESC ENTER 4 12 1 Entering the Node ID Use the A and W keys to select Comm and press ENTER Note The Fault Alarm and Analog Output options are also available in this list box At the following prompt choose one of the following numbers as the Node ID 16 32 48 64 80 96 112 128 144 160 176 192 208 224 or 240 User Comm Node ID Node ID p 16 q POWER ESC ENTER CGA 351 User s Manual Use the A and W keys to scroll the list of available node ID numbers When the desired numb
28. anges we elitr OR ed 11 Sensor Furnace See Furnace Serial Port Baud RGIS si asec enw ba m Yn ARMES 58 Data Bils fe ee tempo hte REA EL aE 58 Node ID beta tii dd 57 Pi EE D set 58 Setting Ubica o KG Pe EE EAR 57 Stop Biis5 viste cx ia aa 58 Typen eree tase e e eis the Bae 59 WIESE seen EX eO XEM 10 103 Software Versions cse x S m e NUMAE A S 61 Spare Parto Last is CM paar EN Boe 87 Specifications General 25e ed esee eres Reds 91 Operating aida E eaten XE Red 92 Stop BIS eS Ts pesci oua Ae Oe vo es rae de OE 58 CGA 351 User s Manual T Temperature Ambient q Vici YE Sur x P Sce RC den a 7 Controls Default o 43 Controls Setting oca acu 35 Minimum ias 4 Operating Aa 91 A od P SN 36 37 38 39 O aa PERRON e ha 4 Terminal Block TBI atendida 10 TR cide ie od Rode RAN EA ER Ans 11 A ra S aude eee wen ae awe Re eee 12 Thermocouple WESCHPIOH 264k ee iid ad as es 2 Replacing io s ot Lee eo ao dul a 82 Testing sei s 71 Voltage vs Temperature T2 IO Oo Bis d cp uS en da Eo De carte Oe 11 Troubleshooting Diagnostic Menu ass 3 cerdo a eL 67 Digital Dip Oe fod te se 76 Furtace eede os AG Beh waders erat d 73 OVETVIEW ee Tne Taini I ar SE 69 A A PD E 73 Thermocouple s iw ta ii As 71 AMIEIIg o 1 oz Ends EA nS Re een a ha eB a 70 U User Program PCCOSSIN DG fen coca aay oh dev e ache ea he a AS 18 27 PASSAT zd eq A Ih Seo ares 16 Security Levels zs oos i a en Tre noo kes Rs 16
29. available in the above list box The following procedures may be performed in this submenu e Analog Output Type configure the analog output for a 0 20 mA 4 20 mA 0 2 V or Namur type Zero Setpoint enter the live measurement value that corresponds to the low end of the analog output range Span Setpoint enter the live measurement value that corresponds to the high end of the analog output range minus the zero setpoint e Test specify a fixed percentage of the analog output range and verify that the correct value is generated Zero Trim adjust the actual output to equal the low end of the analog output range Span Trim adjust the actual output to equal the high end of the analog output range minus the zero setpoint Proceed to the appropriate sub section to program the desired analog output feature 48 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 9 1 Selecting the Analog Output Type Enter the analog output setup menu and proceed as follows User Aout Use the A and Y keys to select Aout Type and press ENTER Zero Setpoint Span Setpoint POWER ESC ENTER Note The Test Zero Trim and Span Trim options are also available in the above list box User Aout Aout Type Use the A and Y keys to 0 20mA select the desired device type 4 20mA and press ENTER 0 2V POWER ESC ENTER
30. content intended for this page 94 CGA 351 User s Manual Appendix A The Nernst Equation Appendix A The Nernst Equation A 1 Introduction The CGA 351 zirconium oxide oxygen analyzer uses the Nernst Equation to calculate the oxygen content of the sample gas When a Yttrium doped zirconium oxide ceramic is heated to a temperature above 650 C it becomes an electrolytic conductor as vacancies in the crystal lattice permit oxygen ions to diffuse into the ceramic If there are different oxygen partial pressures on the two sides of the ceramic cell oxygen ions will migrate along the resulting concentration gradient This constitutes a transfer of electrons from one face of the ceramic to the other If the transferred charge is allowed to accumulate it gives rise to a potential gradient acting in the opposite direction thus tending to oppose further diffusion A 2 Equilibrium Conditions Under equilibrium conditions the potential gradient exactly balances the concentration gradient Porous coatings of a platinum catalyst on both surfaces of the ceramic cell serve as electrodes while still allowing the oxygen molecules to penetrate the coating and diffuse into the ceramic The measured voltage drop across the cell can be directly related to the ratio of the two oxygen partial pressures by means of the Nernst Equation RT P1 Ey nF e m where F the Faraday 96 484 56 coulombs T absolute temperature K K C 273 15
31. described in Chapter 1 General Information Although the standard installation and wiring instructions presented in Chapter 2 Installation still apply in general terms some of the details may vary for different enclosure types C 2 Rack Mount Installation The CGA 351 analyzer is available in a rack mount enclosure for installation in a standard 19 electronics rack see Figure 12 below Zirconia Oxygen Analyzer Figure 12 CGA 351 Rack Mount Version C 2 1 Mounting the Rack Mount CGA 351 Refer to Figure 16 on page 107 for mounting dimensions and install the rack mount CGA 351 as follows 1 Slide the unit into the rack at the desired height 2 Fasten the unit securely to the rack with four screws two on either side of the front panel After the rack mount CGA 351 has been physically mounted into the rack proceed to the next section for connecting the sample system CGA 351 User s Manual 101 Appendix C Optional Enclosures C 2 2 Connecting the Sample System For the best results the sample system should be mounted as close to the CGA 351 analyzer as possible See Figure 13 below for the location of the Swagelok fittings on the rear panel and complete the following steps 1 Using 1 8 stainless steel tubing connect the gas source from the sample system to the Input Gas fitting on the rear panel 2 Using 1 8 stainless steel tubing connect the Sample Output fitting on the rear panel to the gas discharge co
32. gas flow path Thread sealant gives off combustible vapors that can cause reading errors e Do not handle the oxygen sensor with bare hands Although some scratches on the platinum coating can be tolerated rubbing the coating should be avoided Clean the oxygen sensor only by rinsing it with clean water after the sensor has cooled Scrubbing the oxygen sensor or washing a hot sensor in cold water can damage or destroy it Do not disturb the special sealant on the oxygen sensor nut and the inlet fittings Any leakage in these areas will cause inaccurate readings when measuring low oxygen levels CGA 351 User s Manual 15 Chapter 3 Operation 3 3 Powering Up the System Before applying power check the wiring connections and close both enclosures Energize the external disconnect device to power up the CGA 351 For reliable readings allow approximately two hours for the analyzer to reach temperature equilibrium before taking measurements WARNING To prevent corrosion the analyzer must be powered up immediately after introduction of the sample gas If the analyzer is left installed without power the unit s components become susceptible to acid condensation that will cause corrosion If the power must be removed for more than thirty minutes purge the analyzer through the inlet port with a continuous flow of instrument air at a rate of 400 40 cc min IMPORTANT For compliance with the European Union s Low Voltage Directive
33. in ppm should correspond to the certified oxygen content of the calibration gas 5 If the correct ppm reading is not obtained with the calibration gas proceed to the next section to adjust the calibration setting CGA 351 User s Manual 63 Chapter 4 Setup and Calibration 4 14 3 Adjusting the Calibration Setting After the calibration gas flow to the CGA 351 has been established as described in the previous sections the calibration gas setting may be adjusted as necessary To adjust the heater setting complete the following steps 1 Verify that the calibration gas flowing through the analyzer meets the requirements for oxygen content 5 ppm flow rate 400 40 cc min and pressure 1 Atm 2 Make sure that the digital display is configured to read the oxygen concentration in ppm Note The oxygen sensor calibration is actually accomplished by adjusting its operating temperature until the required mV output is achieved 3 Adjust the heater setting as follows 1 Oxygen Press ESC to access the User Program The value shown indicates a 1 0 calibration error 5 05 ppm POWER ESC ENTER Note While in the User Program press ESC at any time to abort the current operation Cfg Opt Disp Use the 4 and gt keys to select Cal and press ENTER POWER ESC ENTER Disp A list of the slots available for calib
34. its optimum calibration gas flow rate based on the testing performed during its factory calibration Typically this value will be 400 40 cc min To set up for calibration complete the following steps 1 Begin the flow of calibration gas to the inlet port of the analyzer at atmospheric pressure 2 Using the flowmeter and needle valve supplied with the analyzer set the calibration gas flow rate to the tagged value 3 Set the digital display to show the oxygen concentration in ppm see Configuring the Digital Display on page 17 At the standard operating temperature of 700 C an oxygen level of 5 ppm corresponds to a raw sensor output of 223 108 mV Note Air calibration at 20 9 O7 0 0 mV is performed during the factory setup Field recalibration of this zero mV point is seldom required Note For other temperature and or oxygen values see Appendix A The Nernst Equation for the expected mV output reading If the analyzer does not respond correctly at the tagged calibration gas flow rate i e the oxygen concentration reading is more than 5 in error the problem is probably due to improper siting of the unit Contact GE for assistance CAUTION Make sure the calibration gas flow rate does not exceed 1 200 cc min 2 5 SCFH Higher flow rates may cool the oxygen sensor below the normal operating temperature and affect the accuracy of measurements or even cause damage to the oxygen sensor The oxygen concentration reading
35. now automatically returns to the Analog Output prompt Using the procedure in Testing the Analog Output on page 52 reset the Test Percent to its normal value Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the analog output 54 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 10 Adjusting the Display Contrast To adjust the contrast of the LCD display enter the User Program and proceed as follows Note Note Cfg Cal Disp POWER ESC ENTER Setup Lock Menus POWER ESC ENTER Use the 4 and gt keys to select Opt and press ENTER A list of the available options is shown Use the A and V keys to select User and press ENTER The Lock All and Versions options are also available in the above list box Analog Output Contrast Backlight POWER ESC ENTER A list of the available options is shown Use the A and V keys to select Contrast and press ENTER The Backlight and Comm options are also available in the above list box User Adjust Contrast Adjust Contrast p 0 q POWER ESC ENTER Use the A and Y keys to increment the value to a number between 35 min contrast and 50 max contrast When
36. ranges To make this feature as flexible as possible the user has the ability to program the following parameters for the Auto Range output Number of ranges to be used 1 2 3 or 4 Units for each range ppm or pent e Zero and span points for each range After the Auto Range feature has been programmed the two CGA 351 Alarms will indicate the specific range that is currently active 4 6 1 Factory Defaults For convenience the CGA 351 is pre programmed at the factory with Auto Range default values that are suitable for many applications These values are listed in Table 3 below Table 3 Auto Range Default Values Units 1 2 3 4 These unit types are NOT programmable by the user For example Range 3 is set for 0 10 pent oxygen and its use is indicated by AR A having a value of 0 and AR B having a value of 1 the meaning of these alarm unit types will become clear in the following sections Proceed to the next sections to learn how to use the Auto Range feature and how to modify the factory default settings 4 6 2 Programming the Auto Ranges To change the default values for the Auto Range feature shown in Table 3 above follow the instructions in this section to set these parameters e Number of ranges e Units e Zero and span points 44 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 6 2a Choosing the Number of Ranges To select the number of ranges proceed as follows f
37. re select the appropriate input parameter through the Disp menu option to restore the digital display 3 6 Converting mV to Oxygen Concentration Although the digital display can show the oxygen concentration in ppm or pcnt and the oxygen sensor output in mV only one parameter can be displayed at any given time Therefore it may sometimes be helpful to manually convert a reading from one form to another Table 2 below provides such information for the full range of the CGA 351 at the typical operating temperature of 700 C Table 2 Oxygen Units Conversions Oxygen pent Oxygen ppmi 1 000 000 10 100 000 1 10 000 0 1 1 000 0 01 100 0 001 10 0 0001 1 0 00001 0 1 The data in Table 2 above was calculated with the Nernst equation See Appendix A The Nernst Equation for details on performing such calculations CGA 351 User s Manual 23 Chapter 3 Operation 3 7 Powering Down When it becomes necessary to power down the CGA 351 for service proceed as follows 1 Press the POWER button just below the digital display 2 Place the external disconnect device into the OFF position CAUTION Never open the door on the sensor enclosure until the sensor has cooled to ambient temperature in about two hours Rapid cooling of a hot sensor will cause cracks in the ceramic sensor Any required service procedures may now be performed 24 CGA 351 User s Manual Chapter 2 Chapter 3 Operatio
38. ttu td db deut Load d ddr 33 4 4 5 Selecting the Operating Mode ui td Ibo DI Qe IIO RUN EEEa debe reeds 34 Setting the Temperature Controls 2 2 ooo di ceed ic ap pp PibIPdsQec sdebcboxiQkebe E doppie der 35 4 SA Entering the Setpoint oec eerte E REO ER Orate tesis Hera Vet A ato rene Cade Ratte d 36 4 5 2 Entering the Sensor Temperature ce ee ee es peur ERE Ein Rr Seabee taeda mE 37 5 s OE AMINO toe tie cose ele nek tte iS ed e eal dd Sa 38 A454 Selecting the Gds MUNG PP Aenean ee ia ic 39 4 5 5 Selecting the Proportional Band zcv eet ite ect teo e ors aa abe uude duni e ERE DRIN ETE 40 oo Setting tne Integration TIT aes tance dis ee danced io eee acca tel peso dens oio acme 41 ANTAS Maximum DY CYC Eia cactus duce tonta ce PR ERR EROR EDDA Fat 42 4 5 8 RESTO Ad Me Default Vales xh cer ue ces E tlds Leda terit as ERO ies 45 oO as a vut or Gers Ac bero oce defui A tate E LIN 44 4 61 Faeterg DSraellts o5 desc Ir creta a coc ee D ec Dec HA TAE RS DE ag A co m ua dece 44 amp 5 2 Programing the ABO RIHOSSS S a bt A RU COO dod ETC ird ad Ed 44 TAG LO DEUSEr MENU Acc 5 cde ee EE Re etr enon a eade power dido etd sce iud 46 Setting Fell AICHE TH score isidro 47 Setting Up the Analog OUTPUT cartas Oy pain o bee e i PEL AU BEE lee Re OER 48 4 9 1 Selecting the Analog Output Type s ts so oat t Dre Cad e EL DER SD Za alg acus ea 49 49 2 Setting the zero SerpDolhba c ots o irs elm ei 50 4 9 3 Setting The Span Sepollb oet da SR M VR Ie pM 51 494 Test
39. used The following calibration gas is recommended by GE e 5ppmOs in N5 IMPORTANT The gas cylinder must be certified as to the exact composition of the calibration gas A calibration gas containing only CO is not recommended since the analyzer will not respond correctly to dry calibration gases that do not contain Hy However CO may be used if moisture is added to the gas by passing it through a saturator or bubbler Uncertainty in the oxygen content of the calibration gas may be a significant source of error in the calibration process A standard certificate of analysis has an uncertainty in the smaller component of 5 For the recommended calibration gas this means an oxygen range of 4 5 5 5 ppm and the corresponding potential calibration errors shown in Table 4 below are introduced Table 4 Calibration Errors Error 225 317 223 108 221 110 As shown in Table 4 above a calibration uncertainty of about 0 95 is introduced by the calibration gas uncertainty alone 62 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 14 2 Regulating the Calibration Gas Flow Rate A temporary connection may be made for calibration purposes However if a permanent connection is preferred it should be as short as possible with an isolation valve right at the calibration gas inlet on the analyzer See the typical sample system in Figure 3 on page 3 for an acceptable arrangement Each CGA 351 is tagged with
40. 270 213 785 259 058 225 788 213 518 256 849 225 317 213 255 254 851 224 856 212 994 253 027 224 405 212 737 251 349 223 964 212 483 249 795 223 532 212 232 248 349 223 108 211 984 246 996 222 693 211 738 245 725 222 286 211 496 244 527 221 887 211 256 243 393 221 495 211 020 242 318 221 110 210 785 241 295 220 732 210 554 240 320 220 361 210 325 239 388 219 997 210 098 238 496 219 638 209 874 237 640 219 286 209 652 236 817 218 939 209 432 236 026 218 598 209 215 235 264 218 263 209 000 234 528 217 933 208 787 233 817 217 608 208 576 233 130 217 288 232 464 216 972 231 819 216 662 231 193 216 356 98 230 586 216 054 CGA 351 User s Manual Appendix B CE Mark Compliance Appendix B CE Mark Compliance B 1 Overview For CE Mark compliance the CGA 351 zirconium oxide oxygen analyzer must meet both the EMC and LVD directives IMPORTANT CE Mark compliance is required for all units used in EU countries B 2 EMC Compliance For EMC compliance the electrical connections must be shielded and grounded as shown in Table 12 below After all the necessary electrical connections have been made seal any unused cable entry holes with standar
41. 6 Specifications Chapter 6 Specifications 6 1 General Specifications Accuracy 0 2 ppm from 0 to 10 ppm 2 of reading for all other ranges Repeatability 1 of reading Reproducibility 0 2 of reading in 24 hours 1 of reading in 30 days Response Time Less than 2 seconds for 90 step change Stability Less than 3 of reading per year Operating Temperature Typical 700 C Maximum 950 C Pressure Effect Less than 0 2 of reading per mm Hg Sample Flow Rate Influence Per 40 cc min flow change at 400 cc min 0 2 ppm from 0 to 10 ppm or 2 of reading Line Voltage Influence 10 nominal line voltage Background Gas Variation Effect Sample gas must be clean dry and free of combustibles For best results use the same background gas for calibration Standard factory calibration is 5 ppm O in N5 Enclosures Standard Wall Mount Optional Rack Mount CGA 351 User s Manual 91 Chapter 6 Specifications 6 2 Operating Specifications Measuring Range Standard factory setup is 0 to 10 ppm for 4 20mA output Field selectable for any portion of the range from 0 1 ppm to 100 Output Range 0 4 to 20 mA 0 to 2 V digital panel meter output 0 to 1000 mV oxygen sensor output Communications Standard RS232 RS485 Serial Port PanaView read only Alarm Circuits Dual alarm contacts Contact rating 2 A 28 VDC SPDT fail safe Sample Requirements Sample
42. 86 Converting mV to ppm ataca 23 98 CGA 351 User s Manual Index D Data Bits cd sace hee ias 58 Dead Spaces eins init 78 Diagnostic Menu A A S 67 Digital Display Backlight Setting criadas eee 56 COMPONCIES 2 tara Soe Lae oe aes 17 Confiture sa o adams rte sb E RESI 17 Contrast Adjusting toe pe Seeds 55 Multiple Windows za ee ERR 22 Output Devices visse ci ex D E ER RA 19 Parameters re rtis va etes dd Rs 18 Replacing vyresi erste eee tee FEES 85 Testi erat rai So kaon de 76 Disconnect Device caia DER Re 7 16 Display See Digital Display E EMC Compliance 5o ser For AO LU ed 99 Enclosure Cover Removing c pia EE Ap REX 9 ElecttoBles Sac yd ee pak A Rex p 1 A 2 sok Oo xe Pre EE ae a Met s 8 E 1 2 Specificatons a eet 91 Environmental FactorS o o oooooooooo oo 7 Errors Oxygen ia Ada 74 F Fault Alarm Setting 5 sa EX MXN 47 Plow Rate Sos iA Mu eu a Coe 2 4 63 92 BiG wieten s oe ria oce AL a OO ee ae tees 2 Forced Flow nico EN TJ Furnace OSCR PHON sei sed et eee eS OAR ae EA 2 D tr Cycle carreie ERES Y E ese 42 Replica a c M e o c MS noe cT 83 Testing i si ead ek ias rad doin 73 Witilgi died e eRERLAG RR UPRERTAGGS hue LE 11 Fuse Rating 5 2 es ex ue Ha ER SE 92 Replacing uc oe eO re RR e x 85 105 111 Index H Heater See Furnace Heater Controla iaa 6 Installation Site SI rM Cu 7 Preparati n i ages uere p WAR RR dE uia 8 Integration Time x os Dex eua xe aue xS 6 41 L Ledks
43. Circuit on page 6 for a discussion of the integration time Use the A and W keys to select Int Time and press ENTER The Setpoint Sensor Temp Air Offset Select Gas Type and Default options are also available in the At the next prompt enter the desired value for the integration time Temp Cntrl Int Time 0000 p POWER ESC ENTER Tem Unit measuring Unit measuring Accept changes Yes No Cancel POWER ESC ENTER Using the 4 and P keys position the cursor under the desired character Then use the A and W keys to increment the value When done press ENTER This message indicates that changes in this menu will alter the live data output To accept the new value use the 4 and gt keys to select Yes and press ENTER The meter now automatically returns to the Temp Control prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the temperature control CGA 351 User s Manual 41 Chapter 4 Setup and Calibration 4 5 7 Setting the Maximum Duty Cycle CAUTION Improper temperature controls settings can seriously degrade the performance of the instrument Never change these settings without specific instructions from GE Enter the temperature control menu and proceed as follows The value selected fo
44. Connect the receive wire to pin 2 c Connect the ground return wire to pin C Connect an analog output device to the 4 20mA pins as follows a Connect the input wire to the external device to pin b Connect the output wire from the external device to pin Connect alarm device s to the ALARM 1 and or ALARM 2 pins as follows a Connect the input wire to the alarm 1 device to pin NO b Connect the output wire from the alarm 1 device to pin C c If desired repeat sub steps a and b to connect alarm 2 Connect any shields to pin G RS232 Transmit TX RS232 Receive RX RS232 Return RTN Any Shield or Ground 4 20mA 2e Analog Output SIG Analog Output SIG NO Normally Open Standard Mode ALARM 1 4 C Common Normally Closed Failsafe Mode Normally Open Standard Mode ALARM 24 Common Normally Closed Failsafe Mode Figure 14 Terminal Block Connections Rear Panel CGA 351 User s Manual 103 Appendix C Optional Enclosures C 2 3b Connecting the Line Power CAUTION Be sure that the input voltage to the CGA 351 complies with the value specified at the time of purchase To connect line power to the rack mount CGA 351 analyzer use the power cable supplied with the unit Plug one end of the cable into the connector on the rear panel and the other end into the power source then flip the power switch to the ON position see Figure 15 on page 105 This compl
45. Entering the Zero and Span Points To enter the zero and span points proceed as follows Num_of_Auto_Ranges Zero_Pct Span_Pct XX XXXXX XXX XXXX A 1 4 POWER ESC ENTER Use the and keys to position the cursor Then use the a and v keys to increment the character to the desired value When done press ENTER The above step will be repeated as many times as necessary to complete the table for the total number of ranges selected on the previous page 4 7 The Opt User Menu After entering the User Program access the Opt User submenu to perform the following operations e Setting the fault alarm type e Setting up the analog output e Adjusting the display contrast e Setting the display backlight e Configuring the serial port Proceed to the appropriate section for specific instructions on the topic of interest 46 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 8 Setting Fault Alarm Type To set up the fault alarm enter the User Program and proceed as follows Cfg Cal Disp Use the 4 and gt keys to select Opt and press ENTER POWER ESC ENTER A list of the available options is shown Use the A and V keys to select User and press ENTER Setup Lock Menus POWER ESC ENTER Note The Lock All and Versions opt
46. MPORTANT For proper operation in the low ranges the oxygen sensor assembly must be replaced as a unit Never attempt to replace just the oxygen sensor itself The oxygen sensor assembly is mounted beneath the sensor furnace and is readily accessible for quick and easy replacement The following items are needed to replace the oxygen sensor e Adjustable wrench e Screwdriver e Pliers CAUTION When replacing the oxygen sensor assembly do not touch the new oxygen sensor with bare hands Handle the assembly by the mounting plate and or manifold WARNING These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively A AN 80 CGA 351 User s Manual Chapter 5 Service and Maintenance 5 5 16 Replacing the Oxygen Sensor Assembly cont WARNING There are extremely hot surfaces in the analyzer Touching these surfaces will result in serious burns Use heat resistant gloves while replacing the oxygen sensor To remove the defective oxygen sensor assembly proceed as follows 1 Remove the inlet and outlet process connections and open the sensor enclosure cover 2 Locate the oxygen sensor and the oxygen sensor clips see Figure 10 on page 89 Use pliers to remove the upper and lower clips from the oxygen sensor The clips are easily removed by pulling them away from the oxygen sensor body 3 Remove the four screws that secure the sensor manifold mounting plate to the bottom of the sensor enclo
47. This circuit constantly monitors the temperature input from an RTD compares it to the set point temperature and turns the heater ON or OFF accordingly The specific type of control circuit a Proportional Integral Derivative PID loop is used because of the adjustable parameters involved Proportional Band Because the system cannot respond instantaneously to temperature changes the actual temperature of the oxygen sensor oscillates about the set point In general increasing the proportional band reduces the magnitude of these temperature oscillations Integral Action A consequence of increasing the proportional band is the introduction of an offset between the set point and the control point The integral portion of the control loop acts to move the control point back toward the set point within a specified period of time Decreasing this integration time reduces the offset more quickly Note A third parameter Derivative Action is not used with the CGA 351 The heater control circuit is configured at the factory for optimum performance Because of the strong interaction between the parameters involved properly setting up the PID loop is a very complex matter As a result randomly changing the P or I parameters can seriously degrade the performance of the CGA 351 IMPORTANT Always contact GE before attempting to change the default P or I values The submenu for performing these changes is password protected to prevent accidental chang
48. User Program or proceed to the appropriate section to continue setting up the alarms 32 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 4 4 Testing the Alarm Relays Enter the alarm setup menu To verify that the alarm relay is functioning properly the alarm may be operated manually as follows Alarms Alarm Feat Use the A and W keys to Trip Value select Test and press ENTER Deadband Value POWER ESC ENTER Note The Trip Type and Fail Safe options are also available in the above list box The following options are available in the TEST submenu e Normal sets the alarm relay to its proper state as dictated by the current live measurement value IMPORTANT Always return the alarm relay to this state at the conclusion of the testing Trip manually triggers the alarm relay to its ON state e Reset manually returns the alarm relay to its OFF state Alarms Alarm Test Use the A and W keys to Normal select the desired TEST z option Press ENTER when one Reset POWER ESC ENTER The meter now automatically returns to the Alarm Features prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the alarms CGA 351 User s Manual 33 Chapter 4 Setup and Calibration 4 4 5 Selecting the Operating Mode
49. alyzer CGA350GP Clean Gas Analyzer CGA350X Clean Gas Analyzer CGA350D Display Unit to which this declaration relates are in conformity with the following standards e EN 61326 1 2006 Class A Table 2 Industrial Locations e EN 61326 2 3 2006 e EN 61010 1 2001 Overvoltage Category II Pollution Degree 2 following the provisions of the 2004 108 EC EMC and 2006 95 EC Low Voltage Directives The units listed above and any ancillary equipment supplied with them do not bear CE marking for the Pressure Equipment Directive as they are supplied in accordance with Article 3 Section 3 sound engineering practices and codes of good workmanship of the Pressure Equipment Directive 97 23 EC for DN lt 25 A A Pf guid i Billerica August 2010 Issued Mr Gary Kozinski Certification amp Standards Lead Engineer SN CE TUV Customer Support Centers U S A The Boston Center 1100 Technology Park Drive Billerica MA 01821 U S A Tel 800 833 9438 toll free 978 437 1000 E mail sensing ge com Ireland Sensing House Shannon Free Zone East Shannon County Clare Ireland Tel 353 0 61 470291 E mail gesensingsnnservices ge com An ISO 9001 2000 Certified Company www ge mcs com en about us quality html WWW ge mcs com 2013 General Electric Company All rights reserved Technical content subject to change without notice 910 199 Rev E
50. and gt keys to select Yes and press ENTER When ready use the 4 and gt keys to select Next and press ENTER 65 Chapter 4 Setup and Calibration 4 14 3 Adjusting the Calibration Setting cont PPM Per Cal Heater Calibrating Heater S xxx T xxx x D xx x POWER ESC ENTER Calibrating Complete Select Finish Back POWER ESC ENTER 1 Oxygen 5 00 ppm POWER ESC ENTER This message appears until the calibration adjustment has been completed usually about 15 30 minutes If the calibration passed use the 4 and gt keys to select Finish and press ENTER The value shown is now the correct ppm value for the oxygen content of the calibration gas Note If the calibration Failed repeat the calibration procedure If another failure occurs contact GE for assistance 4 Discontinue the flow of calibration gas to the analyzer 5 Resume the flow of process gas to the analyzer 6 If necessary reconfigure the digital display to show the desired process parameter The CGA 351 may now be placed back into service 66 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 15 Checking the Current Settings To aid in monitoring the operation of the CGA 351 a built in diagnostics routine is included in the User Program To access th
51. and press ENTER Lock Menus Lock All Versions POWER ESC ENTER Note The User and Setup options also appear in the above list box Because these menus are intended for factory use only specific programming instructions are not presented here However the general purposes of these menus are as follows e Lock Menus this option permits the setting of the security level for any of the individual submenus Lock All this option institutes password protection for all submenus simultaneously Versions this option displays the software versions for each of the system components After responding to any of the above options the meter now automatically returns to the Opt prompt This completes the setting of the option slots and the security levels Either press ESC until you exit the User Program or proceed to the appropriate section of this chapter to continue programming the meter CGA 351 User s Manual 61 Chapter 4 Setup and Calibration 4 14 Calibrating the CGA 351 To calibrate the CGA 351 analyzer the following steps must be completed introduce the chosen calibration gas regulate the calibration gas flow rate adjust the calibration setting as required Proceed with the instructions in this section to calibrate the analyzer 4 14 1 Recommended Calibration Gas To properly calibrate the zirconium oxide oxygen sensor a calibration gas of known composition must be
52. and press ENTER POWER ESC ENTER A list of the available windows is shown Use the A and V keys to select the desired window and press ENTER Cfg Cal Opt 1 Oxygen pent 1 Temperature DegF 1 Oxygen ppm POWER ESC ENTER 1 Oxygen After pressing ENTER at the 3 27 pent previous prompt press ESC and the alternate display appears POWER ESC ENTER 22 CGA 351 User s Manual Chapter 3 Operation 3 5 6 Switching Display Windows cont When configuring the digital display options the following two factors must be considered e Only the digital display and the fault alarm options can be simultaneously assigned to more than one parameter This is because they are virtual devices that are stored in memory The analog output alarm 1 alarm 2 alarm 3 and alarm 4 options can be assigned to only one parameter at any given time This is because they are linked to a specific physical device One must be careful about making changes in the User Program while data is being displayed If the currently selected display input is accidentally deselected the screen reverts to the following x_Unassigned POWER ESC ENTER Although the meter is still collecting data the digital display does not know which information to show Simply
53. ce 5 White Furnace 6 White m power esc enrer N Neutral White Ground unit to protective earth post provided S 90 265 VAC 50 60 Hz 900 W N NOTE For proper operation the unit must be powered by B 11 1I 1I 1I 1I pst 1I 1I I O the voltage specified at the 200000000000 TB1 OUTPUTS Description RS232 Transmit TX RS232 Receive RX RS232 Return RTN Any Shield or Ground Analog Output SIG Analog Output SIG Normally Open Standard Mode time of purchase ES Q DODODODOD Figure 6 CGA 351 Wiring Connections 1208 t NO C NC NO C NC E COMM 4 20mA ALARM 1 ALARM 2 02 TC G z G L 2 HEATER L N G 90 265 VAC FUSE ye O ALARM 1 Common Normally Closed Failsafe Mode A FUSE Normally Open Standard Mode ALARM 2 Common Normally Closed Failsafe Mode CGA 351 User s Manual Inputs Conduit EMT 9 Outputs Power Aa ee Conduit 4 A 250 V TD Time De
54. con at the upper right hand corner of the above display indicates that the User Program is locked with password protection Before any data can be displayed the meter must be configured for the desired display parameter s Enter the User Program by pressing the ESC key and proceed as follows IMPORTANT Jn some applications portions of the User Program may be locked to prevent end user access If this is the case entrance to these submenus requires a special key sequence and a password see page 16 3 5 2 Configuration Options Cal Opt Disp Upon entering the User Program the Cfg option is already selected Simply press ENTER Notice that the Disp option is grayed out at POWER Esc ENTER his ume Disp To proceed with the 1 Cfg option press ENTER To abort the operation press ESC POWER ESC ENTER From 1 Cfg A list of the available display inputs is shown Use the A and W keys to select the desired input and press Sensor ENTER Oxygen has been selected as an example Temperature POWER ESC ENTER Note The CJC Temp and Duty Cycle options are also available in the above list box 18 CGA 351 User s Manual Chapter 3 Operation 3 5 2 Configuration Options cont pent AF From 1 Cfg Oxygen POWER ESC ENTER
55. conia Oxygen Analyzer WARNING Hot surfaces CGA 391 63 4 171 m 37 8 98 gt l POWER f Esc ENTER N Mounting 9 2 112 7 4pl Plate Mounting Hole FRONT VIEW Note Dimensions are in inches millimeters L 63 8 162 SIDE VIEW Figure 5 CGA 351 Mounting Dimensions 13 Chapter 1 Installation TB2 INPUTS Description Pin Sensor Wire Color 1 White 2 White Any Gnd Shield N A N A Yellow Sensor TB3 POWER Description CGA 351 N Color Black Thermocouple TC L Line Thermocouple N A Red ALL Any Gnd Shield G White HEATER Furna
56. ct fuse to use 5 Install the cover on the electronics enclosure and reapply power to the analyzer The CGA 351 may now be placed back into service 5 5 26 Replacing the Digital Panel Meter If the digital panel meter is defective remove the defective meter by completing the following steps Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 1 Disconnect the main power to the CGA 351 WARNING Failure to cut the main power at the external disconnect device before proceeding will result in serious personal injury Remove the four sets of mounting hardware and remove the electronics enclosure from its mounting surface Remove the eight screws on the rear of the enclosure and lift the mounting plate off the enclosure Make a sketch of all wiring connections to the rear of the digital panel meter and then disconnect all the wiring Ur dee ctu sto Remove the two mounting brackets and push the panel meter out through the front of the enclosure Remove the controller and option cards from Slots 1 and 2 respectively CGA 351 User s Manual 85 Chapter 5 Service and Maintenance 5 5 26 Replacing the Digital Panel Meter cont Install the new meter by completing the following steps 1 Install the original controller and option cards into Slots 1 and 2 respectively of the new meter 2 Insert the new meter through the opening in the front of the electronics enclosu
57. d alarm feature Note The setup of Alarm 1 is used as an example in this manual To set up Alarm 2 3 or 4 return to the previous prompt and select the desired option Then repeat the remaining steps CGA 351 User s Manual 29 Chapter 4 Setup and Calibration 4 4 1 Setting the Trip Type Enter the alarm setup menu and proceed as follows Alarms Alarm Feat Use the A and Y keys to select Trip Type and press ENTER Trip Value Deadband Value POWER ESC ENTER Note The Test and Fail Safe options are also available in the above list box Alarms A Trip Type Use the A and W keys to select the desired trip type and press ENTER Below Above with Fault POWER ESC ENTER Note The Below with Fault option is also available in the above list box The meter now automatically returns to the Alarm Features prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the alarms 30 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 4 2 Setting the Trip Value Enter the alarm setup menu and proceed as follows Alarms Alarm Feat Trip Type Trip Value Deadband Value POWER ESC ENTER Use the A and Y keys to select Trip Value and press ENTER Note The Test a
58. d conduit plugs or equivalent Note Ifthe instructions in this appendix are followed the unit will comply with the EMC Directive 2004 108 EC Table 12 Wiring Modifications for EMC Compliance Wiring Modification Use shielded cable to connect power to the CGA 351 2 Select the cable entry closest to the chassis ground Connect the power line ground wire and the shield to the nearest chassis ground terminal Input Output Use shielded cable to interconnect the CGA 351 with any external input output devices Connect the shields to the nearest chassis ground terminal Wires installed in properly grounded metal conduit are not required to have their own shield B 3 LVD Compliance For compliance with the European Union s Low Voltage Directive 2006 95 EC the analyzer requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit Note Ifthe instructions in this appendix are followed the unit will comply with the Low Voltage Directive 2006 95 EC CGA 351 User s Manual 99 Appendix B CE Mark Compliance no content intended for this page 100 CGA 351 User s Manual Appendix C Optional Enclosures Appendix C Optional Enclosures C 1 Introduction Upon request the CGA 35 analyzer may be supplied in an enclosure other than the standard enclosure
59. de In the display electronics the logarithmic signal can be read directly in unlinearized form or it can be converted to a 0 4 20 mA 0 2 V or Namur linearized signal before display Note A temperature above 650 C is required for proper operation of the oxygen sensor Also ambient air is the usual reference gas on the outside of the zirconium oxide sensor The sensor furnace also generates the convective flow that circulates the sample gas through the sample path Pushed from behind by the hot gases still in the furnace the hot sample gas in the sensor furnace rises out of the furnace and cools The cooled sample gases then pass through the outlet port where they are carried away by the main gas flow A platinum coating on the end of the ceramic tube and the zirconium oxide oxygen sensor ensures that all oxidation reduction reactions in the sample gas reach equilibrium It is therefore possible to measure such parameters as excess oxygen in air fuel mixtures and equilibrium oxygen in reducing atmospheres such as hydrogen 4 CGA 351 User s Manual Chapter 1 General Information 15 The Zirconium Oxide Oxygen Sensor The inside and outside of the zirconium oxide oxygen sensor are coated with porous platinum forming two electrodes The sample gas flows past the inside of the sensor while atmospheric air circulates freely on the outside of the sensor This atmospheric air is used as the reference gas for making oxygen measurements s
60. ded in Chapter 4 Setup and Calibration Simply follow those instructions to program the alarm settings listed in Table 1 below Table i Available Alarm Settings Above 0 0 Above 1 0 0 0 The alarms will now respond as described in Table 3 on page 44 That is Alarm 1 will trip when Auto Range 2 or Auto Range 4 is active while Alarm 2 will trip when Auto Range 3 or Auto Range 4 is active Note If fewer than 3 Auto Ranges are being used Alarm 2 may be used for other purposes CGA 351 User s Manual 21 Chapter 3 Operation 3 5 5 Configuring the Analog Output In a manner similar to that used to configure the alarms in the previous section program the analog output with the following settings Note Refer to Chapter 4 Setup and Calibration for detailed programming instructions for the analog output unit type ARng zero set point 0 span set point 100 When configured as specified above the 4 20 mA analog output signal represents 0 100 of the currently active Auto Range 3 5 6 Switching Display Windows After the display has been configured the meter actually maintains multiple display windows Although only one window can be displayed at any given time it is easy to switch to one of the other windows via the User Program Enter the User Program by pressing the ESC key Cfg Cal Opt Disp Notice that the fourth option Disp is now available Use the 4 and gt keys to select Disp
61. done press ENTER The meter now automatically returns to the User prompt This completes the adjusting of the display contrast Either press ESC until you exit the User Program or proceed to the appropriate section of this chapter to continue programming the analyzer CGA 351 User s Manual 55 Chapter 4 Setup and Calibration 4 11 Setting the Display Backlight To set the LCD display backlight enter the User Program and proceed as follows Use the 4 and gt keys to select Opt Then Use the A and W keys to select User and press ENTER Setup Lock Menus POWER ESC ENTER Note The Lock All and Versions options are also available in the above list box User Use the A and W keys to Contrast select Backlight and press ENTER Backlight Comm POWER ESC ENTER Note The Fault Alarm and Comm options are also available in the above list box User Backlight Use the A and Y keys to Off select the desired option and O press ENTER n POWER ESC ENTER Note If Off or On was selected the following prompt does not appear If Timed was selected enter a value below for the length of time without keypad activity that the backlight will be turned Off until further keypad activity is detected User Backlight Timed Use 4
62. ea e A sete E E A E TE 8 25 APIA Analyzer a te PLC TR 9 Ze EWINA the OR PUES e ed cera DUM ec ua 10 25 2 WY UG UC AU SBA A E E ee E EE 11 25 3 A A anie m pet EE X A EE ROO addc dae EEEE Actus a ag 12 Chapter 3 Operation SA pa o A O T 15 3 2 preventing Common Problems eus tod ee rata 15 55 E a LU MM MODE e OD eto RC uM EE 16 3 4 User Program S CUrity 6 nn nnn En ehe eee ea ree 16 3 5 RCO PIPING the Digital DIS llc eraat taret eos ptor eeu o cor MEER IS CR SES 17 5 521 nta Seres DIS DIOIHIS essc cmt nU i eum det tu mired hires bb tients fo ep UNA 17 So 2 Configuration Options senatet at Ee ct irt LOS 18 3 5 3 USING ane Auto RAGS Peter cnr merda ERES cllc mes bob race domos canit 20 Se SACOM TANI the PMS doter e inde Rude a Ecc ake MOM S Ere steals 20 3 5 5 C nfig nng the Andlog OUTPUT 3 cette edo be dd dre eto t ate tte eat las 22 SSA Display AS Dc ertt Ubuntu 22 3 6 Converting mv to Oxygen Concentrado 23 Sf POWERING DOWN a A a 24 CGA 351 User s Manual Contents Chapter 4 Setup and Calibration 4 1 4 2 4 3 44 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 vi VUTEC CUNO anc rt oos des 27 Accessihiguqhe User Program A A A E EE TEE cer ME 27 las My AA EP 28 Setting pte MARRAS a ud Orate lbi deme lobe a a o fissis 28 O e e do oh ce c ane 30 ESP dale AU QL a AT ol AAA II A A A TERR 31 44 3 Setting the Degddband Valus on e eom coro eee Ero e Sale Let t o e ed di 32 ar Taste MS ERR E ERE ESAE HET E
63. ee Figure 4 below Oxygen ions migrate through the zirconium oxide along the concentration gradient Atmospheric O gt Outside Cell Sample O2 Inside Cell Zirconium Oxide Ceramic with Lattice Imperfections From Outside Electrode LSS From Inside Electrode When O concentration in sample gas falls the cell voltage rises with increased oxygen migration through the zirconium oxide Figure 4 Oxygen Migration in the Zirconium Oxide Sensor At the operating temperature of the oxygen sensor the atmospheric reference oxygen is electrochemically reduced at the outer electrode and the resulting oxygen ions seek to equalize with the lower oxygen concentration on the sample side of the cell by migrating through the porous ceramic toward the inner electrode At the inner electrode they give up electrons to become oxygen molecules again and are swept away by the sample flow The lower the concentration of oxygen in the sample gas the greater the rate of ion migration through the ceramic and the higher the cell voltage due to electron exchange at the electrodes The cell voltage rises logarithmically as the amount of oxygen in the sample gas falls allowing the accurate measurement of very low levels of excess oxygen CGA 351 User s Manual 5 Chapter 1 General Information 1 6 The Heater Control Circuit The oxygen sensor temperature in the CGA 351 is maintained by a heater which is part of a complex temperature control loop
64. een converted into a graphical format Use this graph see Figure 11 on page 97 to quickly correlate the analog output voltage reading with the corresponding oxygen percentage at the standard 700 C operating temperature of the meter In addition the data is presented in tabular form in Table 11 on page 98 This table is useful for looking up the correct mV value to enter during the calibration procedure if the data will not be entered directly in either ppm or pcnt oxygen 96 CGA 351 User s Manual Appendix A The Nernst Equation uoleujusou0D uaB xO wdd yo udd widd QOL udd 0001 wdd 000 0L udd 000 001 wdd 000 000 L 96100000 9610000 96100 40 961 9601 96001 oS 2 004 32 AW 1ndino Josues C Figure 11 Oxygen Sensor Output at 700 97 CGA 351 User s Manual Appendix A The Nernst Equation A 3 The CGA 351 Nernst Equation cont Table 11 ppm to mV Conversion at 700 C 305 122 229 995 215 757 290 591 229 421 215 463 282 090 228 862 215 174 276 059 228 317 214 889 271 381 227 786 214 608 267 559 227 269 214 330 264 327 226 763 214 056 261 528 226
65. em is shown in Figure 3 below J To CGA 351 Inlet From CGA 351 Outlet Cmnf SN O CAL GAS INLET SAMPLE SAMPLE INLET OUTLET Figure 3 Typical Sample System CGA 351 User s Manual 3 Chapter 1 General Information 1 4 Principles of Operation A gas sample is drawn into the inlet port of the analyzer by gas diffusion and a forced flow determined by the external sample system The sample gas then flows through a ceramic inlet tube and into the annular space between the inlet tube and the inside of the zirconium oxide oxygen sensor The flowmeter on the outlet port and the needle valve on the inlet port are used to adjust the sample flow rate to 400 40 cc min In the annular sample space the gas is heated to the same 700 C at which the zirconium oxide oxygen sensor is maintained A mV signal is generated This signal is proportional to the logarithm of the ratio of the oxygen concentration in the sample gas to the oxygen concentration in a reference gas contacting the outer electro
66. em to the analyzer Note If more than one analyzer system is being installed be aware that each system is a matched set i e each sensor enclosure must be matched to a specific electronics enclosure Refer to the identification tags on the enclosures to match the systems correctly IMPORTANT For compliance with the European Union s Low Voltage Directive 2006 95 EC the CGA 351 requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit IMPORTANT This symbol indicates Caution risk of electric shock AN Refer to Figure 5 on page 13 and complete the following steps to mount the CGA 351 1 Select a flat surface on a vertical wall or instrument panel with sufficient space to hold the mounting plate with both of the CGA 351 enclosures Note Mount the system in an upright position so that the sample inlet and outlet fittings are on the bottom of the sensor enclosure 2 Using the mounting dimensions shown in Figure 3 on page 13 locate and prepare four 4 mounting holes or two 2 horizontal mounting rails on the vertical surface 3 Secure the system to the mounting surface with four 4 sets of mounting hardware Be sure that the enclosures are in a vertical position with the inlet outlet connectors on the bottom 4 The flowmeter which is fastened to the right side of the se
67. en sensor See Calibrating the CGA 351 on page 62 for the correct procedure 5 3 4 Oxygen Reading Too High This condition is most likely caused either by poor quality reference air a leak in the plumbing or an oxygen sensor that is too cool A brief description of possible solutions to this problem is presented in the next section WARNING The sensor enclosure is hot Use heat resistant gloves when handling the enclosure WARNING This symbol indicates Caution dangerously hot surfaces A 76 CGA 351 User s Manual Chapter 5 Service and Maintenance 5 3 4a Check for Plumbing Leaks A plumbing leak permits contamination of the reference air by the sample gas The resulting reduction in the ratio of the oxygen partial pressures reduces the mV output from the oxygen sensor and yields a percent oxygen reading that is higher than expected Use the following steps to remedy the problem 1 Open the sensor enclosure cover to allow uncontaminated reference air to enter the unit 2 Ifthe oxygen reading drops in Step 1 above tighten all fittings by 1 8 turn and close the sensor enclosure cover If the oxygen reading gradually increases repeat Step 1 If the problem persists proceed to the next section CAUTION Do not tighten fittings more than 1 8 turn at a time 5 3 40 Check the Oxygen Sensor Temperature If the oxygen sensor is below its normal operating temperature the mV output will be too low and the percent oxygen readin
68. ensor enclosure and is easily replaceable The following tools are required e screwdriver e digital multimeter CAUTION To replace the sensor furnace the power to the CGA 351 must be disconnected Therefore replace the sensor furnace and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation WARNING These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively Complete the following steps in the order given to remove the old sensor furnace 1 Disconnect the main power to the CGA 351 WARNING Failure to cut the main power at the external disconnect device before proceeding will result in serious personal injury 2 Open the cover on the sensor enclosure WARNING The sensor furnace may still be hot Always use heat resistant gloves when handling it 3 Remove the oxygen sensor manifold assembly and the thermocouple as described in the previous sections Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 4 Free the sensor furnace from its mounting bracket by removing the two screws on the top and bottom of the furnace and lift the sensor furnace out of the enclosure 5 Locate the ceramic block on the bottom of the sensor furnace and loosen the two 2 terminal screws closest to the outer edge of the sensor furnace IMPORTANT Do not completely remove the termi
69. enter the type of serial port desired User Comm Comm Type Use the A and Y keys to select type of serial port and ENTERI RS 485 pee POWER ESC ENTER The meter now automatically returns to the Node ID Stop Bits prompt This completes the setting of the serial port Either press ESC until you exit the User Program or proceed to the appropriate section of this chapter to continue programming the meter IMPORTANT Check to make sure the communication parameters selected match the settings on the computer 4 13 Setup and Security Settings After entering the User Program access the Opt submenu to perform the following operations e Setting up the option card slots e Setting the security levels Proceed to the appropriate section for specific instructions on the topic of interest 4 13 1 Setting Up the Option Card Slots To set up the option card slots enter the User Program and proceed as follows Cfg Cal Disp Use the 4 and gt keys to select Opt and press ENTER POWER ESC ENTER Use the A and W keys to select Setup and press ENTER Lock Menus POWER ESC ENTER Note The Lock All and Versions options also appear in the above list box CGA 351 User s Manual 59 Chapter 4 Setup and Calibration 4 13 1 Setting Up the Option Card Slots cont CAUTION
70. er Card 256KB SRAM 703 1320 02 Power Supply PCB 703 1350 Basic I O PCB 703 1361 01 Quad Alarm PCB 32K EPROM 703 1376 CGA351 Sensor PCB 703 1362 CGA351 Interconnect PCB CGA 351 User s Manual 87 Chapter 5 Service and Maintenance e no content intended for this page 88 CGA 351 User s Manual Chapter 5 Service and Maintenance Oxygen Sensor Fitting Nut Manifold Sensor Furnace Sensor Furnace bottom Mounting Plate Inlet Fitting Thermocouple Sensor Upper Clip Figure 10 CGA 351 Parts Replacement Sensor Lower Clip Mounting Screw O Bracket 6 pl Inlet Fitting iF Mounting Screw Outlet Fitting Mounting Plate bottom view CGA 351 User s Manual 89 Chapter 5 Service and Maintenance FEA o_O ESS Ss no content intended for this page CGA 351 User s Manual 90 Chapter
71. er is highlighted press ENTER 57 Chapter 4 Setup and Calibration 4 12 2 Entering the Baud Rate At the following prompt choose one of the following values as the serial port baud rate 300 1200 2400 9600 19200 38400 57600 or 115200 User Comm Baud Rate 300 1200 2400 POWER ESC ENTER 4 12 3 Entering the Number of Data Bits Use the A and W keys to scroll the list of available baud rates When the desired rate is highlighted press ENTER At the following prompt enter the number of data bits in each data string Node I Data Length POWER ESC ENTER 4 12 4 Entering the Parity At the following prompt enter the parity setting User Comm Parity Odd Even POWER ESC ENTER 4 12 5 Entering the Number of Stop Bits Use the A and Y keys to select the desired data length and press ENTER Use the A and W keys to select the parity setting and press ENTER At the following prompt enter the number of stop bits in each data string Node ID Stop Bits POWER ESC ENTER 58 Use the A and Y keys to select desired number of stop bits and press ENTER CGA 351 User s Manual Chapter 4 Setup and Calibration 4 12 6 Selecting the Type of Serial Port At the following prompt
72. es 6 CGA 351 User s Manual Chapter 2 Installation Chapter 2 Installation 2 1 Introduction This chapter provides a general description of the standard CGA 351 and gives directions on how to install and wire the analyzer for proper operation Note For information regarding component locations and or wiring connections in an optional enclosure see Appendix C IMPORTANT For compliance with the European Union s Low Voltage Directive 2006 95 EC the CGA 351 requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit WARNING Power up the CGA 351 as quickly as possible after introduction of the sample gas If the analyzer is left installed without power the unit s components become susceptible to acid condensation that will cause corrosion Be sure to observe all installation limits and precautions described in this chapter Pay particular attention to the ambient temperature range of 25 to 50 C 13 to 122 F specified for the instrument WARNING To ensure safe operation of the CGA 351 the unit must be installed and operated as described in this manual Also be sure to follow all applicable local safety codes and regulations for installing electrical equipment In addition all procedures should be performed by trained service personnel 2 2 Choosing an Installation Site
73. ese tasks Enter the User Program see the menu map in Figure 8 on page 25 by pressing the ESC key While in the User Program press ESC at any time to abort the current operation Note Some submenus may be locked and will require a special key sequence and a password for entry see User Program Security on page 16 Cfg Opt Disp Use the 4 and gt keys to select Cal and press ENTER NOTE this screen shows the Disp option as already being configured POWER ESC ENTER As an aid in programming the CGA 351 refer to the menu map Figure 8 on page 25 Proceed directly to the appropriate section to set up and or calibrate the analyzer CGA 351 User s Manual 27 Chapter 4 Setup and Calibration 4 3 The Cal Menu After entering the User Program access the Cal submenu to set the following parameters e Alarm 1 relays e Alarm 2 relays Alarm 3 relays e Alarm 4 relays Temperature controls The calibration and diagnostic portions of this submenu are discussed later in this chapter Proceed to the appropriate section for specific instructions on the topic of interest 4 4 Setting Up the Alarm Relays To set up the CGA 351 s external alarm relays corresponding to the wiring terminals on TB1 proceed as follows Cfg Opt Disp 1 Cal
74. eshooting sequence should resume here Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 1 Disconnect the sensor furnace HEATER leads white 1 2 from terminal block TB2 2 Using a digital multimeter measure the resistance across the disconnected sensor furnace leads One of the conditions listed in Table 7 below should occur Table 7 Sensor Furnace Resistance Reading Resistance Reading Recommended Action approximately 66 ohms The sensor furnace is good check the furnace voltage input see page 74 open loop OL The sensor furnace is bad replace the sensor furnace see page 83 Note The sensor furnace impedance may also be checked in the User Program Proceed to the Diag Impedance prompt as described on page 68 also see Figure 8 on page 25 and display the current value 3 Ifthe sensor furnace is good reconnect the sensor furnace leads to terminal block TB2 Based on the recommended action in Table 7 above proceed to the appropriate section for further instructions CGA 351 User s Manual 73 Chapter 5 Service and Maintenance 5 2 5 Checking the Sensor Furnace Voltage If the sensor furnace impedance test indicated that the sensor furnace is good continue the troubleshooting procedure here Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 1 Using a digital mu
75. etes the wiring of the CGA 351 analyzer C 3 Rack Mount Operation The keypad and LCD display for the rack mount CGA 351 are located on the front panel These items are identical in form and function to those used on the standard enclosure Proceed to Chapter 3 Operation and Chapter 4 Setup and Calibration for instructions on using the analyzer C 4 Rack Mount Service and Maintenance To access the components and wiring in the rack mount CGA 351 it may be necessary to remove the unit from its rack This can be accomplished by disconnecting all cables removing the four mounting screws and sliding the unit out The power cable may then be reconnected C 4 1 Parts Replacement The components included in the Rack Mount CGA 351 are basically the same as in the standard analyzer Those included within the Sensor Enclosure are identical Other components however are located differently in reference to each other See Rack Mount Internal Wiring Connections Figure 17 on page 108 and Rack Mount Major Components Figure 18 on page 109 when following the procedures in Chapter 5 Service and Maintenance 104 CGA 351 User s Manual Appendix C Optional Enclosures C 4 2 Replacing the Fuses If the main power fuses are defective see Figure 15 below and install new fuses by completing the following steps 1 2 3 5 Disconnect the main power to the Rack Mount CGA 351 Insert a screwdriver blade behind the fuse access door to the r
76. f desired repeat sub steps a and b to connect alarm 2 5 Connect any shields to pin G Proceed to the next section to continue wiring the CGA 351 10 CGA 351 User s Manual Chapter 2 Installation 2 5 2 Wiring the Inputs TB2 Terminal block TB2 contains connections for the CGA 351 s sample measurement signals Specifically the following signals are routed to this terminal block e Zirconium oxide oxygen sensor e Thermocouple Sensor furnace All of the connections on terminal block TB2 have already been wired at the factory In the event that one or more of these wires must be reconnected complete the following steps 1 Locate the leads from the zirconium oxide oxygen sensor Connect these leads to terminal block TB2 as follows a Connect the positive sensor wire white 1 to pin b Connect the negative sensor wire white 2 to pin 2 Locate the leads from the thermocouple Connect these leads to terminal block TB2 as follows a Connect the positive thermocouple wire yellow no number to pin b Connect the negative thermocouple wire red no number to pin Note The two thermocouple wires red and yellow are bound together in a brown sheath 3 Locate the leads from the sensor furnace Connect these leads to terminal block TB2 as follows a Connect one furnace wire white 5 to pin 1 b Connect the other furnace wire white 6 to pin 2 Note The polarity of the sensor furnace leads is n
77. flow 400 40 cc min recommended Sample inlet pressure 1 to 10 psig Sample outlet vent pressure 1 atmosphere Ambient Requirements Relative Humidity 0 90 Temperature 25 to 50 C 13 to 122 F Power Requirements 100 115 or 220 240 VAC 50 60 Hz 900 W maximum Fuse 4 A 250 V 5 x 20 mm TD Time Delay European Compliance This unit complies with the 2004 108 EC EMC Directive 2006 95 EC Low Voltage Directive Installation Category II Pollution Degree 2 and Pressure Equipment Directive 97 23 EC in accordance with Article 3 Paragraph 3 Wetted Materials 316 stainless steel ceramic and platinum Connections Sample Inlet and Outlet 6mm or 4 compression tube fitting Power Cable Inlet V conduit Miscellaneous Warm Up Time 30 minutes Calibration Gas certified mixtures of 5 ppm O in N gt 92 CGA 351 User s Manual Chapter 6 Specifications 6 3 Ordering Information Table 10 below shows how the CGA 351 Analyzer Part Number is configured from the options specified A B C D CGA351 Table 10 CGA351 Oxygen Analyzer Ordering Information CATEGORY Model Voltage OPTIONS CGA351 1 100 VAC 50 60 Hz 2 115 VAC 50 60 Hz 3 220 VAC 50 60 Hz 4 240 VAC 50 60 Hz Package 1 Wall Mount 2 Rack Mount Connections CGA 351 User s Manual 1 1 4 inch tube fitting 2 6 mm tube fitting 93 Chapter 6 Specifications no
78. g If any voltage other than 0 00 mV is measured the digital display is defective Contact GE for assistance 5 3 2 Oxygen Reading Above 100 An oxygen display reading greater than 100 is almost always caused by reversed wiring of the oxygen sensor For example 4 oxygen at 700 C would generate an oxygen sensor output of 34 69 mV However reversed oxygen sensor wiring would cause this reading to be 34 69 mV The Nernst equation calculation would then convert this voltage to an oxygen display of 109 4996 e To correct this problem check the oxygen sensor wiring at terminal block TB2 for the correct polarity refer to Figure 6 on page 14 Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 5 3 3 Oxygen Reading Too Low This condition is usually caused by combustibles in the sample gas but it may also be the result of the oxygen sensor being out of calibration To correct the condition complete the following steps 1 The sample gas may be contaminated with combustibles from grease or oil in the plumbing The oxygen sensor will cause combustibles such as CO H or hydrocarbons in the sample to react with oxygen thus depleting the oxygen in the sample gas This will give a reading that may be less than the expected amount of oxygen To fix the problem remove the source of the contamination 2 Ifthe sample gas is not contaminated with hydrocarbons recalibrate the oxyg
79. g procedure must be completed 1 Notify GE Sensing giving full details of the problem and provide the model number and serial number of the instrument If the nature of the problem indicates the need for factory service GE Sensing will issue a RETURN AUTHORIZATION NUMBER RAN and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Sensing instructs you to send your instrument to a service center it must be shipped prepaid to the authorized repair station indicated in the shipping instructions 3 Upon receipt GE Sensing will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken e Ifthe damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e If GE Sensing determines that the damage is not covered under the terms of the warranty or if the warranty has expired an estimate for the cost of the repairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned CGA 351 User s Manual 115 Warranty no content intended for this page 116 CGA 351 User s Manual GE 2 DECLARATION Sensing OF CONFORMITY DOC 0035 Rev A We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA declare under our sole responsibility that the CGA351 Clean Gas An
80. g will be higher than expected Proceed as follows The easiest way to check the sensor temperature is to calibrate the oxygen sensor as described in Calibrating the CGA 351 on page 62 The calibration procedure includes instructions for adjusting the sensor furnace temperature if necessary If the problem has not been resolved by the steps in this section contact GE for assistance 5 4 Calibration Responses Chapter 4 Setup and Calibration describes the procedures for calibrating the CGA 351 in great detail However the response of the unit to the calibration procedures can provide valuable clues to potential problems with the installation The three most common situations are described in this section 5 4 1 Everything Is Fine Calibration of the analyzer at the tagged calibration gas flow rate has been successfully completed Upon switching off the calibration gas the analyzer quickly returns to monitoring and displaying the sample gas concentrations accurately This indicates that proper operating conditions have been achieved and the analyzer can be expected to perform reliably 5 4 2 Forced Flow Problem If a flow rate higher than the tagged calibration gas flow rate is required to calibrate the analyzer the sample gas feed pressure is too high Under such conditions the sample is not entering the oxygen sensor by diffusion only but it is being forced into the sensor instead In addition to the calibration problem sensor l
81. ge 62 5 5 2 The Electronics Enclosure Those components associated with the electronic conditioning of the signals generated by the oxygen measurement components are located in the electronics enclosure This section describes the proper procedures for replacing these parts The user serviceable parts located in the electronics enclosure see Figure 6 on page 14 include the following e Main power fuse Digital panel meter e Controller card e Option card s Proceed directly to the appropriate section to replace any of the above components Note For information regarding component locations and wiring connections in an optional enclosure see 84 Appendix C CGA 351 User s Manual Chapter 5 Service and Maintenance 5 5 2a Replacing the Fuse If the main power fuse is defective install a new fuse by completing the following steps Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 1 Disconnect the main power to the CGA 351 WARNING Failure to cut the main power at the external disconnect device before proceeding will result in serious personal injury 2 Remove the cover beneath the digital display panel on the electronics enclosure 3 Locate the fuse holder see Figure 6 on page 14 on the lower right side of the terminal board Remove the old fuse 4 Install a new fuse of the same type and rating See Chapter 6 Specifications for the corre
82. he actual set configuration Notice that the newly configured display shows the slot number and the input parameter on the top line and the current live value along with the unit type are displayed in the center of the screen Note CGA 351 User s Manual See Chapter 4 Setup and Calibration for instructions on how to adjust the display contrast 19 Chapter 3 Operation 3 5 3 Using the Auto Range Feature The Auto Range feature includes three unit types ARng Auto Range the ratio of the current oxygen reading to the currently active Auto Range expressed as a percentage e AR A Auto Range Alarm A automatically set to a value of 0 or 1 AR B Auto Range Alarm B automatically set to a value of 0 or 1 As an example of how these units work with the default values listed in Table 3 on page 44 consider a situation where the current oxygen reading is 7 5 The Auto Range feature would select the current active range as Range 3 in the table Then 9602 AR Zero ARDE CAR Span AR Zero x 100 75 1 This means that the current oxygen reading represents 75 of the currently active Auto Range In addition to the ARng value calculated above AR A 0 and AR B 1 as shown in the table After programming the Auto Ranges the CGA 351 must be configured to properly handle the Auto Range output To accomplish this the following outputs must be reprogrammed e Alarm A and Alarm B e 4 20 mA analog ou
83. hen done press ENTER POWER ESC ENTER Temp Invalid Output This message indicates that changes in this menu will alter the live data output Press cause invalid output ENTER to continue E K Cancel POWER ESC ENTER Modifying value may Tem Unit Measuring This message indicates that changes in this menu will alter the live data output To accept the new value use the 4 and Yes No Cancel gt keys to select Yes and press ENTER Unit measuring Accept changes POWER ESC ENTER The meter now automatically returns to the Temp Control prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the temperature control 36 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 5 2 Entering the Sensor Temperature Enter the temperature control menu and proceed as follows Temp Cntrl Use the A and V keys to Setpoint select Sensor Temp and press ENTER Air Offset POWER ESC ENTER Note The Select Gas Type Prop Band Int Time Max Duty Cycle and Default options are also available in the above list box At the next prompt enter the desired value for the air offset Temp C Sensor Temp Using the 4 and gt keys p
84. ife may be shortened and analyzer plugging may occur If forced flow is confirmed as the problem refer to Chapter 2 Installation for instructions on proper installation of the analyzer CGA 351 User s Manual 77 Chapter 5 Service and Maintenance 5 4 3 Plugging or Dead Space Problem The analyzer was successfully calibrated at the tagged calibration gas flow rate and the analyzer responded quickly to the calibration gas However there is a significant delay in reading the correct sample gas concentrations after turning off the calibration gas When this problem occurs it is very likely that the sample gas inlet is located in a dead space After the analyzer is correctly reading the sample gas concentration switch on the calibration gas just long enough to get the correct reading As soon as the analyzer reads the correct value quickly shut off the calibration gas One of two responses should occur 1 If the recovery time is still too long the sample gas path through the oxygen sensor may be plugged with particulates Use of a blowback system contact GE for assistance should clear the analyzer and restore proper operation 2 Ifthe analyzer reading recovers promptly dead space is the likely problem Internal structures can cause dead spaces that are not evident from an external examination It may sometimes be necessary to relocate the analyzer to a more suitable installation site Note If the calibration Failed repeat
85. ight of the power switch and pry it open Using needle nose pliers pull each of the two fuse holders with an arrow printed on the end straight out of the unit Replace the fuses with new ones of the same type and rating See Chapter 6 Specifications for the correct replacement fuse to use Reinsert the fuse holders making sure the arrows are pointing down and close the fuse access door The Rack Mount CGA 351 may now be placed back into service Fuse Access Door Fuse Holder Power Switch Screwdriver Fuse Holder Power Connector Figure 15 Rack Mount Fuse Locations CGA 351 User s Manual 105 Appendix C Optional Enclosures no content intended for this page 106 CGA 351 User s Manual Appendix C Optional Enclosures 17 15 436 Dimensions are in inches millimeters 19 78 502 18 67 474 18 25 464 0 90 23 tel A Figure 16 CGA 351 Rack Mount Version Outline and Mounting Dimensions Zirconla Oxygen Analyzer
86. im and Span Trim options are also available in the above list box At the next prompt enter the desired test percent value which is the analog output value expressed as a percentage of the analog output span used by the meter as a test signal User Aout Aout Test Use 4 and gt to position the Test Percent cursor Then use A and V to increment the test percent to P the desired value 0 v Enter the desired test percent at the above prompt to verify that the analog output device is accurately recording the specified test values When done press ENTER IMPORTANT The edit box above must be exited by pressing ENTER while in edit mode and re entered for the analog output device to drive the previously entered value Entering the span or zero trim spin boxes will also output the entered test percent The meter now automatically returns to the Analog Output prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the analog output 52 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 9 5 Setting the Zero Trim Using the procedure in Testing the Analog Output on page 52 set the Test Percent to 0 At the analog output setup menu proceed as follows User Aout Test Span Trim Zero Trim POWER ESC ENTER Use the A and Y keys to select
87. in this manual In addition be sure to follow all applicable local safety codes and regulations for installing electrical equipment In addition all procedures should be performed by trained service personnel WARNING These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively AR A 78 CGA 351 User s Manual Chapter 5 Service and Maintenance 5 5 1 The Sensor Enclosure Those components associated with the oxygen measurement process are located in the sensor enclosure This section describes the proper procedures for replacing these parts WARNING There are extremely hot surfaces in the sensor enclosure If these surfaces are touched serious burns could result Always wear heat resistant gloves while performing these procedures WARNING These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively CAUTION Rapid cooling of the oxygen sensor will result in cracks in the ceramic that will render the sensor unusable Before opening the door to the sensor enclosure allow about two hours after the system is powered down for the sensor to cool slowly Proceed to the appropriate section to replace the desired component 5 5 1a Replacing the Oxygen Sensor Clips The oxygen sensor is connected to the electronics via two contact clips located at the base of the sensor The upper clip is electrically isolated from the lower clip by a non conductive band on
88. includes the components shown in Figure 7 below Display Window Cursor Control Keypad CGA 351 Power ESC enter POWER Button ESO Button ENTER Button Figure 7 Digital Display Panel A typical display will be configured to the customer s needs at the factory If changes are required follow the instructions in this section to complete the initial configuration of the digital display As an aid in performing this task refer to the menu map in Figure 8 on page 25 3 5 1 Initial Screen Displays Immediately upon power up the digital display shows the following sequence of informational screens as the meter performs its internal systems checks BSeries Loader v1 05 Boot is Flash Program CRC valid Booting from Flash Scanning Hardware Found Image Slot 1 Downloading Slot 1 Scanning Hardware Initializing Machine Initializing UI CGA 351 User s Manual This is a typical example of the first initialization screen This is a typical example of the second initialization screen This is a typical example of the final initialization screen 17 Chapter 3 Operation 3 5 1 Initial Screen Displays cont If the meter passes all of its internal system checks the following screen appears 1 Oxygen 8 This is a typical example of an initial screen Heater Warming Note The padlock i
89. ing tne Andlog DUDE tt ls da 52 4 95 Se AIC A e o e 53 AE Setting THES DOE TRIN ence ves asian ter sete ot ette ees E te A ete anh e de 54 Adj sting the DI piau T ODEIOSE S ise dH orar to terr tulere to teen sues Poi eT ies DI De aue Ree e di 55 Setting the Display BOCRIO E n tin t c teu ph E Ta ipm a a EL ud dad 56 Setting e UP ELA d 57 412 tEnterngthe Nodes D go scd adobe puer aa 5f 2 12 2 Entering the Baud Rate oe castoeePEREPINASURHEUEERP INSERERE RE EN ned Aden EE More io otto 58 A12 3 Ehtering the Number of Data Bits ser ser notr sry wists seti rores e Ere b Acide vor Fr sae SS 58 apo cnet D ETHUpasse a rite n e ri TS dederat le NC a 58 4 12 5 Entering the Number of SIDES oo i PER ett Ce e Sd ola e SE Ea 58 4 12 6 Selecting the Type of Serial Port cit oru e EO fo pd ER HD Fr C RS 59 Set pdnd Security SRT Sc ao ad o acne vds ate Cassi tse sisse resa utt boc Art aes tence Zebee 59 ASAS Up the Option Card SOUS esis ere to PC Eo Ee eek Deam v De o VR RM aa aerate 59 CGA 351 User s Manual Contents 413 2 Setting TE A ere cue o ad 61 ATA Calibrating the SAA EE ET ts eats IA A aah ine 2 62 4 14 1 Recommended Calibration GOISS c e cae ode a sco da eR Hc 62 4 14 2 Regulating the Calibration Gas Flow Rate 45 bU t tio aaa dans Rete ER er E aes 63 4 14 3 Adjusting the Calbraton Se tidad 64 4 15 Checking the Current SSEIDgs 2 i t2c2cc 40k n ir ds td era 67 4 15 1 Checking the sensor Impedance ous aa mr te Dalt aes caesar Vet
90. ions are also available in the above list box User Use the A and Y keys to select Fault Alarm and press ENTER Analog Output l l Contrast POWER ESC ENTER Note The Backlight and Comm options are also available in the above list box User Fault Alarm Use the A and Y keys to Non Fail Safe select the desired alarm type and press ENTER Fail Safe POWER ESC ENTER The meter now automatically returns to the User prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the user options CGA 351 User s Manual 47 Chapter 4 Setup and Calibration 4 9 Setting Up the Analog Output To set up the CGA 351 s analog output enter the User Program and proceed as follows Cfg Cal Eg POWER ESC ENTER Disp Setup Lock Menus POWER ESC ENTER User Fault Alarm Analog Output Contrast POWER ESC ENTER Use the 4 and gt keys to select Opt and press ENTER A list of the available options is shown Use the A and V keys to select User and press ENTER Use the A and Y keys to select Analog Output and press ENTER Note The Backlight and Comm options are also
91. is submenu proceed as follows 1 Oxygen 2 71 ppm POWER ESC ENTER Press ESC to access the User Program Note While in the User Program press ESC at any time to abort the current operation Cfg Opt Disp Slct Cal Menu Item POWER ESC ENTER Cfg Opt Disp 2 Cal POWER ESC ENTER Setup Cal Slct Cal Menu Item POWER ESC ENTER CGA 351 User s Manual Use the 4 and gt keys to select Cal and press ENTER A list of the slots available for calibration is shown Use the A and W keys to select 1 Cal and press ENTER Use the 4 and gt keys to select Diag and press ENTER 67 Chapter 4 Setup and Calibration 4 15 1 Checking the Sensor Impedance Enter the Diag menu as described on page 67 and proceed as follows Use the A and Y keys to select Impedance and press Impedance ENTER View Temp Controls l POWER ESC ENTER Sensor Impedance The oxygen sensor impedance in ohms is shown Press Impedance xxx xx ENTER to continue ES POWER ESC ENTER The meter now automatically returns to the Cal prompt This completes the checking of the sensor impedance Either pre
92. lay 5 x 20 mm 14 Chapter 3 Operation Chapter 3 Operation 3 1 Introduction The CGA 351 is an easily operated monitoring device Before applying power make sure the system has been installed in accordance with the instructions given in Chapter 2 Installation Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C Allow the unit to warm up for at least thirty minutes prior to use Check to see if it is hot Observe all normal safety precautions Specifically do not exceed the maximum pressure and temperature ratings of the zirconium oxide oxygen sensor and the sample system This chapter includes discussions of the following topics preventing common problems powering up the system configuring the digital display taking measurements WARNING To ensure safe operation of the CGA 351 it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations for installing electrical equipment 3 2 Preventing Common Problems Use the CGA 351 to accurately measure low oxygen levels To avoid problems observe the following e Check the calibration of the analyzer once or twice a week for the first month of operation and once every 2 3 months thereafter see Chapter 4 Setup and Calibration for instructions e Never use thread sealant on any connection in the sample
93. low the digital display panel which is fastened with six 6 Phillips head screws The PC Board has terminal blocks TB1 12 connections TB2 8 connections and TB3 3 connections mounted on it Proceed to the appropriate sub section to wire each of these terminal blocks CGA 351 User s Manual 9 Chapter 2 Installation 2 5 1 Wiring the Outputs TB1 Terminal block TB1 contains connections for the CGA 351 s output signals Specifically the following signals are available at this terminal block e Serial port e 0 4 20 mA 0 2 V or Namur analog output e Alarm relays To wire any or all of these output signals complete the following steps 1 Attach a cable or conduit with the appropriate number of conductors to an entry port on the bottom of the electronics enclosure 2 To connect a serial port from a personal computer use the COMM pins on terminal block TB1 as follows a Connect the transmit wire to pin 1 b Connect the receive wire to pin 2 c Connectthe ground return wire to pin C 3 To connect an analog output device use the 4 20mA pins on terminal block TB1 as follows a Connect the input wire to the external device to pin b Connect the output wire from the external device to pin 4 To connect alarm device s use the ALARM 1 and or ALARM 2 pins on terminal block TB1 as follows a Connect the input wire to the alarm 1 device to pin NO b Connect the output wire from the alarm 1 device to pin C c I
94. ltimeter measure the sensor furnace AC input voltage on terminal block TB2 See Figure 6 on page 14 for the location of TB2 and the HEATER pins One of the conditions listed in Table 8 below should occur Table 8 Furnace Voltage Reading Voltage Reading Recommended Action approximately Defective digital display unit replace the full line voltage digital display see page 85 no voltage present There is no power reaching the sensor furnace proceed with the next step 2 Remove the terminal board fuse see Figure 6 on page 14 and check it for continuity If the fuse is blown replace it with a new fuse of the same size and type listed in Chapter 6 Specifications 3 Ifthe fuse was good the main voltage supply is bad Check the external disconnect device and or the main voltage source to that device Based on the recommended action in Table 8 above proceed to the appropriate section for instructions If the problem has still not been resolved at this point contact the factory for assistance 5 3 Oxygen Measurement Errors This section discusses each of the following possible oxygen errors e Oxygen concentration stuck at 20 93 Oxygen concentration reading above 10096 Oxygen reading too low Oxygen reading too high Refer to the appropriate section of this chapter and to Figure 10 on page 89 for help in troubleshooting each of the above situations Note For information regarding component locations and wiring co
95. mple gas to the optimum temperature of 700 C e A thermocouple precisely regulates the temperature of the oxygen sensor and the sample gas e Aninlet needle valve and an outlet flowmeter adjust the sample gas flow to 400 40 cc min O Furnace Bracket Sensor Furnace GA Flowmeter Oxygen Sensor Manifold Electrical Conduit Figure 2 Sensor Enclosure 2 CGA 351 User s Manual Chapter 1 General Information 1 3 The Sample System In addition to the components supplied with the CGA 351 an external sample system may be required to ensure that the analyzer is fed a properly conditioned sample or calibration gas stream In particular the gas must be clean and dry and it must be delivered to the analyzer at atmospheric pressure Note A suitable sample system which will be supplied completely assembled on its own mounting plate may be ordered directly from GE Commonly used sample system components include filters pressure regulators pressure gauges by pass loops and sample pumps It is recommended that stainless steel construction be used for all wetted parts of the sample system A typical sample syst
96. n submenu security levels customized for each unit see table below Oxygen 0 Display Non Fail Safe 0 Fault Alarm Fault Alarm Fail Safe 0 Analog Output Temperature Sensor 2 Alarm 1 2 Alarm 2 AOut Type 2 Alarm 3 2 Alarm 4 CJC Temp Above Zero Setpoint Span Setpoint Duty Cycle Trip Type Below Alarm 1 Above with Fault Below with Fault Test Analog Output Zero Trim Span Trim Alarm 2 Trip Value Enter Value Adjust Contrast Contrast Off Alarm 3 Deadband Value Enter Value Alarm 4 On Backlight Normal Enter Time min
97. n the reference air is contaminated by the same gases that are being measured the oxygen sensor generates a 0 00 mV analog output signal and a 20 93 oxygen reading Opening the cover permits uncontaminated reference air to enter the unit If opening the cover and fixing any plumbing leaks does not cause the 20 93 reading to drop proceed to the next section 3 Ifthe oxygen reading drops in Step 2 above tighten all fittings by 1 8 turn and close the sensor enclosure cover If the oxygen reading gradually returns to 20 93 try tightening the fittings an additional 1 8 turn If the problem persists contact GE for assistance CAUTION Do not tighten fittings more than 1 8 turn at a time CGA 351 User s Manual 75 Chapter 5 Service and Maintenance 5 3 1 Checking the Digital Display If the shorted wiring and plumbing leak checks have not corrected the problem complete the following steps 1 Disconnect the oxygen sensor O2 leads from terminal block TB2 2 Connect the positive lead of a digital voltmeter to the wire white 1 removed from pin and connect the negative voltmeter lead to the wire white 42 removed from pin IMPORTANT The oxygen sensor leads must be removed from the terminal block for this test If the leads are not disconnected a short on the digital display circuit board could result in a false 0 00 mV reading 3 A voltage reading of 0 00 mV should be obtained to correspond with the 20 9396 oxygen readin
98. nal screws from the ceramic power block 6 Carefully remove the two leads from the loosened terminal screws near the outer edge of the sensor furnace CGA 351 User s Manual 83 Chapter 5 Service and Maintenance A A _ 5 5 1d Replacing the Sensor Furnace cont This completes the removal of the old sensor furnace Install the new sensor furnace immediately by completing the following instructions 1 2 Locate the ceramic block which is located on the bottom surface of the new sensor furnace Feed each of the previously removed sensor furnace wires through the outside then the inside of the ceramic block Reconnect the two wires to the outer terminals on the ceramic block Make sure the internal power leads are fed all the way through the ceramic block in order to make a good connection and that they exit on the opposite side from which they were inserted Tighten all four 4 terminal screws on the ceramic block Using a digital multimeter check the resistance of the sensor furnace heating element Specific instructions may be found on page 73 Reinstall the thermocouple and the oxygen sensor manifold assembly into the sensor enclosure as described on page 81 starting with step 3 Close the cover on the sensor enclosure This completes the replacement of the sensor furnace Reconnect the main power to the unit and recalibrate the oxygen sensor see Calibrating the CGA 351 on pa
99. nd Fail Sate options are also available in the above list box At the next prompt enter the desired trip point value 000 00 p Alarms Trip Value POWER ESC ENTER Using the 4 and gt keys position the cursor under the desired character Then use the A and V keys to increment the value When done press ENTER The meter now automatically returns to the Alarm Features prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the alarms CGA 351 User s Manual 31 Chapter 4 Setup and Calibration 4 4 3 Setting the Deadband Value Enter the alarm setup menu and proceed as follows Alarms Alarm Feat Trip Type Trip Value Deadband Value POWER ESC ENTER Use the A and W keys to select Deadband Value and press ENTER Note The Test and Fail Safe options are also available in the above list box At the next prompt enter the desired deadband value Alar Trip Deadband 000 00 p POWER ESC ENTER Using the 4 and P keys position the cursor under the desired character Then use the A and W keys to increment the value When done press ENTER The meter now automatically returns to the Alarm Features prompt Either press ESC until you exit the
100. nd dry gas stream The analyzer can accurately measure oxygen levels from 0 1 ppm to 100 O and can even measure oxygen content in reducing gases This is accomplished with a precision temperature controlled zirconium oxide zirconia oxygen sensor The standard CGA 351 analyzer as shown in Figure I below is supplied in a pair of stainless steel enclosures mounted side by side on a metal plate with a 40 flexible conduit connecting the two This compact wall mounted system includes the following components e A sensor enclosure which contains the oxygen sensor sensor furnace thermocouple inlet port with needle valve outlet port with flowmeter and interconnecting cable s and e An electronics enclosure which contains the temperature control circuitry output signal processing circuitry digital display user interface and wiring terminal strips The CGA 351 analyzer is also available in optional enclosures see Appendix C for more information Zirconia Oxygen Analyzer Figure 1 Standard CGA 351 Analyzer CGA 351 User s Manual 1 Chapter 1 General Information 1 2 The Sensor Enclosure The sensor enclosure which is shown in Figure 4 below houses the sample measurement components The functions of these components are as follows e A zirconium oxide zirconia oxygen sensor converts the oxygen concentration of the sample gas into a mV output signal e A sensor furnace heats the oxygen sensor and the sa
101. nd use of natural resources for its production It may contain hazardous substances that could impact health and the environment In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources we encourage you to use the appropriate take back systems Those systems will reuse or recycle most of the materials of your end life equipment in a sound way The crossed out wheeled bin symbol invites you to use those systems If you need more information on the collection reuse and recycling systems please contact your local or regional waste administration Visit http www ge mcs com en about us environmental health and safety 1741 weee req html for take back instructions and more information about this initiative iv CGA 351 User s Manual Contents Chapter 1 General Information 1 1 1 2 1 3 1 4 1 5 1 6 gh eors Fan 6 M TL bd 1 TNE SEMSOl ENCIOSUTE O cota 2 The Sample A A A Jani a c ir UP dale a ce bee tet 3 Principles of ORC BEIDE Loses E A A icu Jamie O SNT 4 TheZirconium DAS OXYGEN SENSON es saco o do alten ce reves wa at 5 The eater CON ROC IFGUIE 23 cd as eror Atel Duo Muri et LO e to do e 6 Chapter 2 Installation Zak pagos AAA At etat pt ae te dae Seti Fed eL a eee VET EPU IU SIM 7 22 CHOOSING amInstollatiok Sites ucro mp Polo eo o o ER ES e A ra aM teet 7 25 Mounting TNE Shao O A aa ie eee Roo o eee ee 8 24 Connecting the sSdmple Syste N ee i
102. nnection on the Sample System Note If desired a suitable sample system may be ordered directly from GE The sample system would be supplied fully assembled on a flat plate with four 4 mounting holes Gas Fittings BYPASS OUTPUT po SAMPLE he INPUT GAS Ga e Power Connection Output Connections Figure 13 CGA 351 Rack Mount Version Rear Panel C 2 3 Wiring the Rack Mount CGA 351 The rack mount CGA 351 requires the same electrical connections as the standard version but the wiring to PC Board terminal strips TB1 TB2 and TB3 has already been done at the factory The only remaining connections to be made are at the rear panel terminal strip for those outputs being used see Figure 13 above and Figure 14 on page 103 C 2 3a Connecting The Outputs The terminal block on the rear panel provides connections for the CGA 351 s output signals The following signals are available e Serial port e 0 4 20 mA 0 2 V or Namur analog output e Alarm relays 102 CGA 351 User s Manual Appendix C Optional Enclosures C 2 3a Connecting the Outputs cont All of the connections on this terminal block are optional in that they are not required for proper operation of the analyzer To wire any or all of these output signals refer to Figure 14 below and complete the following steps which apply 1 Connect a serial port from a personal computer to the COMM pins as follows a Connect the transmit wire to pin 1 b
103. nnections in an optional enclosure see Appendix C 74 CGA 351 User s Manual Chapter 5 Service and Maintenance 5 3 1 Oxygen Concentration Reads Constant 20 93 This condition is unusual and is likely to be caused either by a short in the oxygen sensor wiring a severe air leak in the plumbing or a defective digital display A brief description of how to remedy this problem is presented below WARNING The sensor enclosure is hot Use heat resistant gloves when handling the enclosure WARNING This symbol indicates Caution dangerously hot surfaces AR 5 3 1a Checking the Oxygen Sensor Wiring Refer to Figure 10 on page 89 for the location of the oxygen sensor clips and check for a short circuit in the contact clip wiring two wires touching If this does not correct the problem proceed to the next section Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 5 3 16 Checking for Plumbing Leaks A plumbing leak permits cross contamination of the reference air and the sample gas Use the following steps to remedy the problem 1 Make sure that the calibration gas port in the sample system has not been left open This would admit atmospheric air into the sample system and force a 20 93 reading 2 Open the sensor enclosure cover and check all plumbing connections for leaks Make sure that the oxygen sensor nut and the inlet connections are properly sealed Whe
104. nsor enclosure Touching any of these surfaces without heat resistant gloves will result in serious burns Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 1 Locate the thermocouple TC leads on pin yellow no number and pin red no number on terminal block TB2 2 Using a digital multimeter measure the voltage across the TC terminals One of the conditions listed in Table 5 below should occur Table 5 TC Voltage Reading at 700 C Voltage Reading Recommended Action 25 31 mV The temperature is good proceed to the oxygen sensor check see page 73 lt 25 mV The temperature is low proceed to the sensor furnace check see page 73 0 mV reading The TC is defective proceed to the TC replacement instructions see page 82 3 Complete the action recommended in Table 5 above Note Ifa voltage reading other than those listed above is obtained refer to Figure 9 on page 72 and or Table 6 on page 72 to determine the operating temperature of the sensor furnace A standard CGA 351 operates at a temperature of 700 C Based on the recommended action in Table 5 above proceed to the appropriate section for further instructions CGA 351 User s Manual 71 Chapter 5 Service and Maintenance 5 2 2 Checking the Thermocouple cont 72 ES o w a S E LL o lt x a o gt w o
105. nsor enclosure is connected to the discharge port on the bottom of the unit with a length of 6mm stainless steel tubing Make sure that the factory installed Swagelok fittings are secure 5 A flow control valve is attached to the inlet port on the bottom of the sensor enclosure with 6mm stainless steel tubing and Swagelok fittings Point the valve in the proper direction to receive the inlet piping from the sample system and securely tighten the fittings 2 4 Connecting the Sample System The sample system should be located so that it is able to deliver a sample at a flow rate of 400 40 cc min For best results mount the sample system as close as possible to the CGA 351 An ideal location would be on the same panel just below the analyzer If there are questions consult with an applications engineer at the factory See Figure 5 on page 13 and complete the following steps to connect the sample system to the analyzer 1 Using 6mm stainless steel tubing or 4 stainless steel tubing with adaptors connect the gas source from the sample system to the Swagelok fitting on the flow control valve at the inlet port on the analyzer 2 Using 6 mm stainless steel tubing or 1 4 stainless steel tubing with adaptors connect the Swagelok outlet fitting at the top of the flowmeter on the analyzer to the gas discharge connection on the sample system Note If desired a suitable sample system may be ordered directly from the factory The sample
106. on Internal Wiring Connections MAIN PRINTED CIRCUIT BOARD Q CGA 351 User s Manual 108 Appendix C Optional Enclosures Sensor Enclosure see Figure 5 2 NO Output Terminal Block Gas Fittings co Zirconia Oxygen Analyzer WARNING Hot surfaces Mp EXEIEIEIEIEJEIEREHEIEZER 1 zu m EHE Main Printed Circuit Board Digital Panel Meter CGA 351 User s Manual E po Sample Meter Bypas
107. osition the cursor under the desired character Then use 000 the A and V keys to p increment the value When done press ENTER Sensor Temp POWER ESC ENTER Tem Unit Measuring This message indicates that changes in this menu will alter the live data output To accept the new value use the 4 and Yes No Cancel gt keys to select Yes and press ENTER Unit measuring Accept changes POWER ESC ENTER The meter now automatically returns to the Temp Control prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the temperature control CGA 351 User s Manual 37 Chapter 4 Setup and Calibration 4 5 3 Setting the Air Offset CAUTION Improper temperature controls settings can seriously degrade the performance of the instrument Never change these settings without specific instructions from GE Enter the temperature control menu and proceed as follows Temp Cntrl Use the A and W keys to select Air Offset and press Sensor Temp ENTER Air Offset l l Select Gas Type POWER ESC ENTER Note The Setpoint Prop Band Int Time Max Duty Cycle and Default options are also available in the above list box At the next prompt enter the desired value for the air offset
108. ot important 4 Connect the ground wire white 4G and any shields to either of the pins labeled G This completes the wiring of terminal block TB2 Proceed to the next section to continue wiring the CGA 351 CGA 351 User s Manual 11 Chapter 2 Installation 2 5 3 Wiring the Line Power TB3 Terminal block TB3 contains connections for the line power to the CGA 351 To wire the line power complete the following steps WARNING Before proceeding with the section verify that the line power has been turned off at the external disconnect device 1 Attach a cable or conduit with the three line power conductors to an entry port on the bottom of the electronics enclosure CAUTION Be sure that the input voltage to the CGA 351 complies with the value specified at the time of purchase If the voltage is incorrect contact the factory immediately 2 Connect the line power leads to terminal block TB3 as follows a Connect the line power lead black to pin L b Connect the neutral power lead white to pin N c Connect the ground power lead green to the protective earth ground post identified by e This completes the wiring of the CGA 351 analyzer Proceed to Chapter 3 Operation for instructions on using the analyzer 12 CGA 351 User s Manual Chapter 1 Installation CGA 351 User s Manual 17 432 15 1 4 387 8 1 4 208 7 3 8 187 Zir
109. press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the analog output 50 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 9 3 Setting the Span Setpoint Enter the analog output setup menu and proceed as follows User Aout Test Zero Setpoint Span Setpoint POWER ESC ENTER Note At the next prompt enter the desired span setpoint 0000 00 p User Aout Span Set POWER ESC ENTER Use the A and W keys to select Span Setpoint and press ENTER The Test Zero Trim and Span Trim options are also available in the above list box Use 4 and gt to position the cursor under the desired character Then use A and V to increment the value Press ENTER when done The meter now automatically returns to the Analog Output prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the analog output CGA 351 User s Manual 51 Chapter 4 Setup and Calibration 4 9 4 Testing the Analog Output Enter the analog output setup menu and proceed as follows User Aout Use the A and Y keys to select Test and press Span Setpoint ENTER Zero Trim POWER ESC ENTER Note The Aout Type Zero Tr
110. r this parameter indicates the percentage of time that the heater receives power Thus a larger number results in a faster heat up to operating temperature while a smaller number results in a slower Note heat up Temp Cntrl Int Time Max Duty Cycle Default POWER ESC ENTER Note above list box At the next prompt enter the desired value for the duty cycle Duty Cycle 000 p Temp Cn Duty Cycle POWER ESC ENTER Tem Unit Measuring Unit measuring Accept changes Yes No Cancel POWER ESC ENTER Use the A and Y keys to select Max Duty Cycle and press ENTER The Setpoint Sensor Temp Air Offset Select Gas Type and Prop Band options are also available in the Using the 4 and P keys position the cursor under the desired character Then use the A and V keys to increment the value When done press ENTER This message indicates that changes in this menu will alter the live data output To accept the new value use the 4 and gt keys to select Yes and press ENTER The meter now automatically returns to the Temp Control prompt Either press ESC until you exit the User Program or proceed to the appropriate section to continue setting up the temperature control 42 CGA 351 User s Manual Chapter
111. ration is shown Use the A and W keys to select 1 Cal and press ENTER POWER ESC ENTER Setup Diag Use the 4 and gt keys to select Cal and press ENTER Slct Cal Menu Item POWER ESC ENTER 64 CGA 351 User s Manual Chapter 4 Setup and Calibration 4 14 3 Adjusting the Calibration Setting cont POWER ESC ENTER PPM Percent Percent POWER ESC ENTER Use the A and Y keys to select Heater and press ENTER Use the A and W keys to select PPM and press ENTER At the next prompt enter the correct value for the oxygen concentration in ppm Refer to Appendix A The Nernst Equation to determine the corresponding sensor output in mV CGA 351 User s Manual PPM Percent PPM 000 00 p POWER ESC ENTER PPM Invalid Output Modifying value may cause invalid output Yes No POWER ESC ENTER PPM Percent Cal Gas Start the Calibration Gas Back Next Cancel POWER ESC ENTER Using the 4 and P keys position the cursor under the desired character Then use the A and W keys to increment the value When done press ENTER Use the 4
112. re and secure it in place with the two brackets 3 Reconnect all of the wires to the connectors on the rear of the new digital panel meter 4 Place the mounting plate over the rear of the electronics enclosure and secure it with the eight screws previously removed 5 Mount the electronics enclosure back onto the wall panel and secure it with the four sets of hardware previously removed 6 Reconnect the main power to the analyzer 7 Referto Chapter 3 Operation and Chapter 4 Setup and Calibration to reprogram the new digital panel meter The CGA 351 is now ready to be placed back into service Replacing the Controller Card To replace a defective controller card complete the following steps Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C 1 Disconnect the main power to the CGA 351 WARNING Failure to cut the main power at the external disconnect device before proceeding will result in serious personal injury Remove the panel meter as described in the previous section Remove the defective controller card from Slot 1 of the panel meter and install the new controller card in its place Reinstall the panel meter into the electronics enclosure as described in the previous section above Reconnect the main power to the analyzer Bx Y m A Refer to Chapter 3 Operation and Chapter 4 Setup and Calibration to reprogram the new digital panel meter The
113. rmocouple clamp to the bottom of the sensor furnace 6 Extract the thermocouple from the sensor furnace through the opening in the bottom of the sensor enclosure Install the new thermocouple by completing the following steps 1 Insert the new thermocouple into the sensor furnace being careful not to strike it against the heating element or the pipe wall inside the sensor furnace 2 Secure the thermocouple clamp to the bottom of the sensor furnace with the screw previously removed 3 Route the thermocouple wires through the conduit and into the electronics enclosure 4 Connect the thermocouple wire leads to the same pins from which the old leads were removed The positive yellow and negative red leads must be connected with the correct polarity 5 Reinstall the oxygen sensor manifold assembly into the bottom of the sensor enclosure and install the upper and lower oxygen sensor clips as described in the previous section 6 Close the covers on both enclosures This completes the replacement of the thermocouple 7 Energize the main power to the meter and calibrate the oxygen sensor see Calibrating the CGA 351 on page 62 82 CGA 351 User s Manual Chapter 5 Service and Maintenance _ _ _ BhBD __ Sm SS ee 5 5 1d Replacing the Sensor Furnace The sensor furnace which maintains the oxygen sensor at a stable operating temperature is located in the s
114. rom the Main Menu POWER ESC ENTER Cal Diag Slct Cal Menu Item POWER ESC ENTER Cal Temp Control Auto Range Line Voltage POWER ESC ENTER Num of Auto Ranges Enter Num of Range X p POWER ESC ENTER Use the A and v keys to select 1 Cal and press ENTER Use the 4 and gt keys to select Setup and press ENTER Use the A and v keys to select Auto Range and press ENTER Use the a and v keys to increment the value to a number between and 4 When done press ENTER Note Ifa number less than 1 is entered above the setting will default to 1 Auto Range If a number greater than 4 is entered above the setting will default to 4 Auto Range CGA 351 User s Manual 45 Chapter 4 Setup and Calibration 4 6 26 Selecting the Units To select the units to be used proceed as follows A Auto Range Units PCT_Table PPM_ Table POWER ESC ENTER Use the a and v keys to select the desired units table and press ENTER Note Entry of the zero and span points for all ranges will be made in the units selected above Internally the CGA 351 will automatically convert the data into the non selected units 4 6 2c
115. rt ELA DULATER ES alte o de ed 68 4 15 2 Viewing the Hedter Settlgs cnc duos rea bete aute ah UU geet as m recu pese eR ae Dd 68 Chapter 5 Service and Maintenance cNMMIs isis arse rM v T EE 69 Bees General TrOLDIeSPGOU ED ecc aci Mo etica eoi ttt e teet xp WO tao c enata Ee E Me 69 A the VV isis irr esie re ter A tiers petto ula A 70 5 2 2 Checking the dhelWiaesuee riis da eu tat ach etu t e tie dt t tuc E Ado CREE 71 5 2 5 Checking the OSUOSBES BHSULDS c2 Gea Cat PCR ER RUE Nt ho e E bt c i o eta 73 5 2 4 Checking the Sensor FUrnaCe seein dacs ao ds cl 73 5 2 5 Checking the Sensor Furnace Voltage ac terres venatus Cr rr ade EPOR IRR AS deserted 74 53 Oxygen Measurement EFFOFS i serre esee taa e E efe tus 74 5 3 1 Oxygen Concentration Reads Constant 20 9396 coo vce eo cse ks er RR Ia ARE ER eR E es 75 5 3 2 Oxygen Reading Above 100 cs c ous Seco dte ta tee Ne ee Nae d t RU eU cela ee oL 76 53 3 Ode Redding TOO LOW S isti ea Does toties ci A atte a uc O LITE A UEM et 76 5 34 DNUS Redding TON S 2 ood eodd aa al n tcc niu tl brates dla ae pud ay 76 542 Calibration os esses ca oam idascatu ea tee hel he nU RS LM Se kerr bene 77 RAAN EVCLEMI MGS Pie ies ie at EEEE AE Coo Ut T 77 be Eorced FIOWPIDBISIT S ce Coe e te Miet eo ed daa ido ct frd 77 5 4 3 Plugging or Dead Space Problem n n de ed De tei et 78 5 57 Parts Replacement cria e or O e Cin n 78 531 The SensonEnclos Urb ta iia 19 5 5 2 The Electronics EnclOSUEG esce REC
116. s Meter Figure 18 CGA 351 Rack Mount Version Major Components 109 Appendix C Optional Enclosures E E Sa RN NNNM NR NE NN no content intended for this page CGA 351 User s Manual 110 A Alarms Deadband Value es ey eet ye I RE dE 32 Eanlt ee isi ae a A pu AG 47 PeatHes orice bch ed ahora he DERE ExqEuS 29 Mode ii ora dida nee 34 Settinte AA wand Qe dO ene Boe PALA 28 Specific tions dada 92 o s wa TENA ono aede 33 THp LY pe adco d uacette Igea au NEQU S 30 Trip Value iv xci opes a TCR ER RC ORE 31 Wingse eus dd e a dea nds etg ees 10 103 Analog Output Namlib sara y Dd ee Pea te Ete FEN teh ded 49 Qutp t Dype caro dew hdeXMee rex ie eds 49 Setting Upei oed tar epu eg IE RR RIEN 48 Span Setpoint amp ise es Ge E sr RUE A 51 Span Trim ex v S USER RUE RSEN EA 54 A EN Ete OS E Ree e 52 Winge i ev ane Sax UE ex 10 103 Zeto Setpoint uev Love Sax VN eS DR de 50 FOTO Vii es o od da lud fur E 33 B Backlight Setting ve ea eer EE URS 56 Ba d Rate tdi rata 58 C Calibration A A 64 EA ues qu A Meee mr ONE SA 27 Gas Flow Rallies o T RN SES 63 Oxy sen Sensor s jo eae epu rein n IEEE APR 62 Plumbing Connections ooooooooooo o 63 Recommended Gases veri E e v e 62 Responses os ane naa eee qa eX NE Rar 77 CE Mark Compliance xvii da 99 Common Problems Preventing 15 Connecting See Part Name Contrast Adjusting lt a 55 Controller Card Replacing
117. ss ESC until you exit the User Program or proceed to the next section of this chapter to continue checking the settings 4 15 2 Viewing the Heater Settings Enter the Diag menu as described on page 67 and proceed as follows Setup Cal Use the A and Y keys to Impedance select View Temp Controls and press ENTER View Temp Controls POWER ESC ENTER View Temp Controls The current temperature SetP Prop IntT Duty control settings are shown Press ENTER to continue XXX XXXX XXXX XXX ik POWER ESC ENTER Note The four values shown are the current setpoint proportional band integration time and maximum duty cycle The meter now automatically returns to the Diag prompt This completes the viewing of the heater settings Press ESC until you exit the User Program 68 CGA 351 User s Manual Chapter 5 Service and Maintenance Chapter 5 Service and Maintenance 5 1 Introduction The CGA 351 has been designed to provide years of trouble free operation However because of the technical challenges involved in measuring very low levels of oxygen some difficulties may occasionally be encountered The procedures for resolving many of these situations are discussed in this chapter If the information provided in this chapter is insufficient to solve the problem please contact the factory for further assistance
118. sure Make sure that the sensor does not hit the sides of the sensor furnace and carefully slide the sensor assembly out of the enclosure IMPORTANT Note the orientation of the mounting plate and the manifold while removing the assembly CAUTION When replacing the oxygen sensor assembly do not touch the new oxygen sensor with bare hands Handle the assembly by the mounting plate and or manifold To install the new oxygen sensor complete the following steps 1 Insert the sensor manifold assembly through the opening in the bottom of the sensor enclosure and into the sensor furnace Make sure that the assembly is oriented in the same way as the old assembly CAUTION Ifthe sensor furnace is hot insert the new oxygen sensor slowly Take 45 60 seconds to fully insert the sensor into the furnace If the sensor is inserted too quickly it will crack Secure the mounting plate to the bottom of the enclosure with the four screws previously removed Reinstall the upper and lower clips onto the oxygen sensor body Connect the inlet and outlet process fittings to the bottom of the sensor enclosure Close the cover on the sensor enclosure A nu PF YS BK Calibrate the new oxygen sensor as described in Calibrating the CGA 351 on page 62 This completes the replacement of the oxygen sensor assembly CGA 351 User s Manual 81 Chapter 5 Service and Maintenance 5 5 1c Replacing the Thermocouple The thermocouple is mounted on the bo
119. system would be supplied fully assembled on a flat plate with four 4 mounting holes 8 CGA 351 User s Manual Chapter 2 Installation 2 5 Wiring the Analyzer The system components which are housed in the sensor enclosure have already been wired at the factory These include e Oxygen sensor TB2 Thermocouple TB2 e Sensor furnace TB2 To completely wire the CGA 351 zirconium oxide oxygen analyzer the following items must be connected e Serial port TB1 e Analog output TB1 e Alarm relays TB1 e Line power TB3 Refer to the wiring diagram shown in Figure 6 on page 14 while completing the instructions in this section WARNING In order to meet CE Mark requirements all cables must installed as described in Appendix B CE Mark Compliance IMPORTANT For compliance with the European Union s Low Voltage Directive 2006 95 EC the CGA 351 requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit WARNING To ensure safe operation of the CGA 351 the unit must be installed and operated as described in this manual Also be sure to follow all applicable local safety codes and regulations for installing electrical equipment In addition all procedures should be performed by trained service personnel To access the terminal printed circuit board remove the cover be
120. the calibration procedure see Calibrating the CGA 351 on page 62 If another failure or any situations not covered in this chapter are encountered contact GE for assistance 5 5 Parts Replacement The CGA 351 is designed to enable easy and quick servicing if necessary This section describes the replacement of major and minor components of the analyzer However before actually replacing any component carefully read the complete instructions to become familiar with the procedures Each procedure in this section includes a list of the equipment needed to complete the component replacement Please make sure that any necessary replacement parts are on hand before dismantling the analyzer In addition the first paragraph of each section gives a description of the function and location of the part to be replaced refer to Figure 10 on page 89 while following the step by step instructions in this section Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C CAUTION Ifthe power must be disconnected to replace a part perform the replacement as quickly as possible The CGA 351 is susceptible to corrosion from acid condensation if it remains without power for more than thirty minutes If service procedures not covered in this chapter become necessary please contact GE for assistance WARNING To ensure safe operation of the CGA 351 it must be installed and operated as described
121. the sensor body Both clips simply snap around the body of the sensor The following tools are needed to replace the oxygen sensor clips e Pliers e Wire cutters Wire strippers e Crimping tool CGA 351 User s Manual 79 Chapter 5 Service and Maintenance 5 5 1a Replacing the Oxygen Sensor Clips cont Power may remain on while completing the following steps 1 Open the sensor enclosure cover 2 Locate the oxygen sensor and the oxygen sensor clips see Figure 10 on page 89 Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C IMPORTANT Never touch the coating on the oxygen sensor with bare hands 3 Use pliers to remove the upper and lower clips from the oxygen sensor The clips are easily removed by pulling them away from the oxygen sensor body 4 Cut off the old upper clip leaving the remaining wire as long as possible gn Strip 1 2 of insulation off the upper clip wire and slide the new upper clip over the stripped wire Using a crimping tool crimp the new upper clip onto the upper clip wire Repeat steps 4 and 5 to install the new lower clip Reinstall both clips onto the oxygen sensor body 6 7 8 Close the cover on the sensor enclosure 9 Recalibrate the oxygen sensor as described in Calibrating the CGA 351 on page 62 This completes the replacement of the oxygen sensor clips 5 5 16 Replacing the Oxygen Sensor Assembly I
122. tput 3 5 4 Configuring the Alarms The first step in setting up the alarms is to assign the correct unit types To accomplish this proceed as follows from the Main Menu Cal Opt Disp Upon entering the User Program the Cfg option is already selected Simply press ENTER POWER ESC ENTER Sem Cal Opt Disp To proceed with the 1 Cfg option press ENTER POWER ESC ENTER 20 CGA 351 User s Manual Chapter 3 Operation 3 5 4 Configuring the Alarms cont From 1 Cfg A list of the available display inputs is shown Use the A and v keys to select the Oxygen input and press Sensor ENTER Temperature POWER ESC ENTER From 1 Cfg Oxygen A list of the available unit ARng types is shown Use the a AR A and v keys to select the AR A option and press ENTER AR B POWER ESC ENTER Note The ppm pcnt and AF options are also available above From 1 Cfg Ox AR A Follow the instructions on 2 Alarm 1 page 19 to select Alarm 1 as the desired output for the AR A 2 Alarm 2 unit type Add Remove MO Cancel POWER ESC ENTER Repeat the previous steps to assign the AR B unit type to Alarm 2 Detailed instructions for setting up the alarms are provi
123. ttom of the sensor furnace and extends approximately 2 3 in into the sensor furnace Note For information regarding component locations and wiring connections in an optional enclosure see Appendix C CAUTION To prevent damage the oxygen sensor must cool for about two hours after the unit is powered down before the sensor enclosure door may be opened Then replace the thermocouple and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation WARNING These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively A standard screwdriver is the only tool needed for replacement of the thermocouple Complete the following steps in the order shown to remove the defective thermocouple 1 Disconnect the main power to the CGA 351 WARNING Failure to disconnect the main power at the external disconnect device before proceeding will result in serious personal injury 2 Open the cover on the sensor and electronics enclosures WARNING The sensor furnace may still be hot Always use heat resistant gloves when handling it 3 Remove the oxygen sensor manifold assembly as described in the previous section 4 Disconnect the thermocouple leads from TB2 in the electronics enclosure make a note of the terminal pins for each lead and pull the leads through the conduit and into the sensor enclosure 5 Remove the screw that secures the integral the

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