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GE CGA 351, User Manual

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GE CGA 351 User Manual Download Page 91

Service and Maintenance

5-13

December 2004

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.

IMPORTANT:

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.

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Summary of Contents for CGA 351

Page 1: ...Oxygen Analyzer User s Manual 910 199C December 2004 The Model CGA 351 is a GE Panametrics product GE Panametrics has joined other GE high technology sensing businesses under a new name GE Infrastructure Sensing www DataSheet4U com www DataSheet4U com ...

Page 2: ...urse of dealing or usage or trade Return Policy If a GE Infrastructure Sensing Inc instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Infrastructure Sensing Inc 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 Infrastructure...

Page 3: ...the Model CGA 351 2 3 Connecting the Sample System 2 4 Wiring the Analyzer 2 5 Wiring the Outputs TB1 2 6 Wiring the Inputs TB2 2 7 Wiring the Line Power TB3 2 8 Chapter 3 Operation Introduction 3 1 Preventing Common Problems 3 1 Powering Up the System 3 2 User Program Security 3 2 Configuring the Digital Display 3 3 Initial Screen Displays 3 4 Configuration Options 3 5 Switching Display Windows 3...

Page 4: ...put Type 4 18 Setting the Zero Setpoint 4 19 Setting the Span Setpoint 4 20 Testing the Analog Output 4 21 Setting the Zero Trim 4 22 Setting the Span Trim 4 23 Adjusting the Display Contrast 4 24 Setting the Display Backlight 4 25 Setting Up the Serial Port 4 26 Entering the Node ID 4 26 Entering the Baud Rate 4 26 Entering the Number of Data Bits 4 27 Entering the Parity 4 27 Entering the Number...

Page 5: ...oo Low 5 9 Oxygen Reading Too High 5 9 Calibration Responses 5 11 Everything Is Fine 5 11 Forced Flow Problem 5 11 Plugging or Dead Space Problem 5 11 Parts Replacement 5 12 The Sensor Enclosure 5 13 The Electronics Enclosure 5 20 Recommended Spare Parts 5 24 Chapter 6 Specifications General Specifications 6 1 Operating Specifications 6 2 Ordering Information 6 3 Appendix A The Nernst Equation Int...

Page 6: ...roduction C 1 Rack Mount Installation C 1 Mounting the Rack Mount C 1 Connecting the Sample System C 2 Wiring the Rack Mount C 2 Rack Mount Operation C 4 Rack Mount Service and Maintenance C 4 Parts Replacement C 4 Replacing the Fuses C 5 www DataSheet4U com www DataSheet4U com ...

Page 7: ...Chapter 1 www DataSheet4U com www DataSheet4U com ...

Page 8: ...l Information Introduction 1 1 The Sensor Enclosure 1 2 The Sample System 1 3 Principles of Operation 1 4 The Zirconia Oxygen Sensor 1 5 The Heater Control Circuit 1 6 www DataSheet4U com www DataSheet4U com ...

Page 9: ...ted side by side on a metal plate with a 40 flexible conduit connecting the two This compact wall mounted system includes the following components 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 an electronics enclosure which contains the temperature control circuitry output sign...

Page 10: ...en sensor and the sample gas to the optimum temperature of 700 C a thermocouple precisely regulates the temperature of the oxygen sensor and the sample gas an inlet needle valve and an outlet flowmeter adjust the sample gas flow to 1 000 150 cc min 2 1 0 3 SCFH Figure 1 2 Sensor Enclosure FurnaceBracket Flowmeter Thermocouple NeedleValve Sensor Furnace OxygenSensor Manifold Electrical Conduit Flow...

Page 11: ...le sample system which will be supplied completely assembled on its own mounting plate may be ordered directly from the factory 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 system is shown in Figure 1 3 b...

Page 12: ... 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 zirconia sensor The sensor furnace also generates the convective flow that circulates the sample gas ...

Page 13: ...rous 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 o...

Page 14: ...egral 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 C...

Page 15: ...Chapter 2 www DataSheet4U com www DataSheet4U com ...

Page 16: ...Installation Introduction 2 1 Choosing an Installation Site 2 2 Mounting the Model CGA 351 2 3 Wiring the Analyzer 2 5 www DataSheet4U com www DataSheet4U com ...

Page 17: ... 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...

Page 18: ...e 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 F 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 programmin...

Page 19: ...ll 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 2 1 on page 2 9 locate and prepare four 4 mounting holes or two 2 horizontal mounting rails on the vertical surf...

Page 20: ...connect the sample system to the analyzer 1 Using 6mm stainless steel tubing or 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 6mm stainless steel tubing or stainless steel tubing with adaptors connect the Swagelok outlet fitting at the top of the flowmeter on the analyze...

Page 21: ... Directive 73 23 EEC 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 saf...

Page 22: ...inal block TB1 as follows a Connect the transmit wire to pin 1 b Connect the receive wire to pin 2 c Connect the 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...

Page 23: ... 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 t...

Page 24: ...ry 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...

Page 25: ... 406 11 1 2 292 9 1 2 241 3 1 2 89 6 3 4 171 7 3 8 187 6 3 8 162 SIDE VIEW FRONT VIEW 16 406 14 1 4 362 7 8 22 7 8 22 8 1 4 208 3 7 8 98 15 1 4 387 17 432 Ø1 2 Ø12 7 4pl Mounting Hole Mounting Note Dimensions are in inches millimeters Plate www DataSheet4U com www DataSheet4U com ...

Page 26: ... Normally Closed Failsafe Mode TB1 OUTPUTS HEATER TC Thermocouple Furnace Any Gnd Shield 1 2 Furnace G G Any Gnd Shield Thermocouple O2 Group Description TB2 INPUTS Pin Sensor Sensor ALL ALL 6 White 5 White N A G White N A Red N A Yellow 2 White 1 White Wire Color G TB3 POWER N L Pin 5 x 20 mm Size 3 A FUSE Type Rating Anti Surge 90 265 VAC 50 60 Hz 250 W NOTE For proper operation the unit must be...

Page 27: ...Chapter 3 www DataSheet4U com www DataSheet4U com ...

Page 28: ... 3 1 Preventing Common Problems 3 1 Powering Up the System 3 2 User Program Security 3 2 Configuring the Digital Display 3 3 Converting mV to Oxygen Concentration 3 8 Powering Down 3 8 www DataSheet4U com www DataSheet4U com ...

Page 29: ...e to follow all applicable local safety codes and regulations for installing electrical equipment Preventing Common Problems Use the CGA 351 to accurately measure low oxygen levels To avoid problems observe the following 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 Calibrating the Model CGA 351 on page 4 31 Nev...

Page 30: ... 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 User Program Security The CGA 351 has been equipped with a User Program 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 f...

Page 31: ... 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 3 2 on page 3 9 Display Window ESC Button ENTER Button Cursor Control Keypad POWER Button www DataSheet4U com www DataSheet4U ...

Page 32: ...Program by pressing the ESC key and proceed as follows IMPORTANT In 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 3 2 BSeries Loader v1 05 This is a typical example of the first initialization screen Boot is Flash Program CRC valid Booting from Flash Scan...

Page 33: ...pt Disp To proceed with the 1 Cfg option press ENTER To abort the operation press ESC 1 Cfg POWER ESC ENTER From 1 Cfg A list of the available display inputs is shown Use the and keys to select the desired input and press ENTER Oxygen has been selected as an example Oxygen Temperature Sensor POWER ESC ENTER From 1 Cfg Oxygen A list of the available unit types is shown Use the and keys to select th...

Page 34: ...e 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 See The Opt User Menu on page 4 15 for instructions on how to adjust the display contrast Switching Display Windows After the display has been configured the meter actually maintains multiple display win...

Page 35: ...nges in the User Program while data is being displayed If the currently selected display input is accidentally deselected the screen reverts to the following Although the meter is still collecting data the digital display does not know which information to show Simply re select the appropriate input parameter through the Disp menu option to restore the digital display Cfg Cal Opt Disp A list of th...

Page 36: ...ation for details on performing such calculations 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 ...

Page 37: ...pe Test Fail Safe Enter Value Enter Value Above Below Normal Trip Reset Non Fail Safe Fail Safe 1 Cfg Sensor Temperature Oxygen CJC Temp Duty Cycle 0 Fault Alarm 0 Display 2 Alarm 1 2 Alarm 2 ppm pcnt deg C deg F mV deg C deg F pcnt Disp as selected in 1 Cfg menu Cfg Cal Alarms 2 Cal Setup 1 Cal User Baud Rate Data Length Parity Stop Bits Comm Type Security Level Key Sequence Password No Yes Yes Y...

Page 38: ...Chapter 4 www DataSheet4U com www DataSheet4U com ...

Page 39: ...Controls 4 8 The Opt User Menu 4 15 Setting Fault Alarm Type 4 15 Setting Up the Analog Output 4 16 Adjusting the Display Contrast 4 24 Setting the Display Backlight 4 25 Setting Up the Serial Port 4 26 Setup and Security Settings 4 28 Calibrating the Model CGA 351 4 31 Checking the Current Settings 4 36 www DataSheet4U com www DataSheet4U com ...

Page 40: ... 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 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 instructi...

Page 41: ...o the appropriate section for specific instructions on the topic of interest 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 Cal Opt Disp Use the and keys to select 2 Cal and press ENTER 1 Cal 2 Cal POWER ESC ENTER Setup Use the and keys to select Setup and press ENTER Setup Slct Cal Menu Item POWER ESC E...

Page 42: ...ts the manual triggering and resetting of the alarm relay to verify that it is working properly 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 desired 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 selec...

Page 43: ...prompt enter the desired trip point value 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 Alarms A Trip Type Use the and keys to select the desired trip type and press ENTER Above Below Above with Fault POWER ESC ENTER Alarms Alarm Feat Use the and keys to selec...

Page 44: ... 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 Alarms Alarm Feat Use the and keys to select Deadband Value and press ENTER Trip Type Trip Value Deadband Value POWER ESC ENTER Alar Trip Deadband Using the and keys position the cursor under the desired character Then use the and keys to incre ment th...

Page 45: ...ORTANT Always return the alarm relay to this state at the conclusion of the testing Trip manually triggers the alarm relay to its ON state Reset manually returns the alarm relay to its OFF state 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 Alarms Alarm Feat U...

Page 46: ...mal 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 The meter now automatically returns to the Alarm Features prompt Press ESC until you exit the User Program Alarms Alarm Feat Use the and keys to select Fail Safe and press ENTER Deadband Value Test Fail Safe POWER ESC ENTER Alarms Fail ...

Page 47: ...change these settings without specific instructions from GE Infrastructure Sensing Proceed to the appropriate sub section to program the desired temperature control feature Cfg Cal Opt Disp Use the and keys to select 1 Cal and press ENTER 1 Cal 2 Cal POWER ESC ENTER Setup Cal Diag Use the and keys to select Setup and press ENTER POWER ESC ENTER Setup Cal Use the and keys to select Temp Control and...

Page 48: ...opriate section to continue setting up the temperature control Temp Cntrl Use the and keys to select Setpoint and press ENTER Setpoint Air Offset Prop Band POWER ESC ENTER Temp Cntrl Set Point Using the and keys position the cursor under the desired character Then use the and keys to incre ment the value When done press ENTER Setpoint 000 s POWER ESC ENTER Temp Invalid Output This message indicate...

Page 49: ... 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 Temp Cntrl Use the and keys to select Air Offset and press ENTER Setpoint Air Offset Prop Band POWER ESC ENTER Temp Cn Air Offset Using the and keys position the cursor under the desired character Then use the and keys to incre ment the v...

Page 50: ...al band 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 Temp Cntrl Use the and keys to select Prop Band and press ENTER Setpoint Air Offset Prop Band POWER ESC ENTER Temp Cntrl Prop Using the and keys position the cursor under the desired character Th...

Page 51: ...me 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 Temp Cntrl Use the and keys to select Int Time and press ENTER Air Offset Prop Band Int Time POWER ESC ENTER Temp Cntrl Int Time Using the and keys position the cursor under the desired character Then...

Page 52: ...he above list box At the next prompt enter the desired value for the duty cycle 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 Temp Cntrl Use the and keys to select Max Duty Cycle and press ENTER Prop Band Int Time Max Duty Cycle POWER ESC ENTER Temp...

Page 53: ... 4 31 before reliable readings are obtained Note The Setpoint Air Offset and Prop Band options are also available in the above list box The meter now automatically returns to the Temp Control prompt Press ESC until you exit the User Program From Temp Control Use the and keys to select Default and press ENTER Int Time Max Duty Cycle Default POWER ESC ENTER Tem Unit Measuring This message indicates ...

Page 54: ...nterest Setting Fault Alarm Type To set up the fault alarm enter the User Program as described on page 4 1 and proceed as follows Note The Backlight and Comm options are also available in the above list box Cfg Cal Opt Disp Use the and keys to select Opt and press ENTER POWER ESC ENTER Cfg Cal Opt Disp A list of the available options is shown Use the and keys to select User and press ENTER User Se...

Page 55: ...lows Note The Backlight and Comm options are also available in the above list box Fault Alarm Use the and keys to select the desired alarm type and press ENTER Non Fail Safe Fail Safe POWER ESC ENTER Cfg Cal Opt Disp Use the and keys to select Opt and press ENTER POWER ESC ENTER Cfg Cal Opt Disp A list of the available options is shown Use the and keys to select User and press ENTER User Setup Loc...

Page 56: ...nt enter the live measurement value that corresponds to the high end of the analog output range minus the zero setpoint 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 t...

Page 57: ...a 4 20 mA output to be clamped in specific bands to indicate out of range errors Note 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 User...

Page 58: ...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 User Aout Use the and keys to select Zero Setpoint and press ENTER Aout Type Zero Setpoint Span Setpoint POWER ESC ENTER User Aout Zero Set Use and to position the cursor under the desired char acter Then use and to increm...

Page 59: ...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 User Aout Use the and keys to select Span Setpoint and press ENTER Aout Type Zero Setpoint Span Setpoint POWER ESC ENTER User Aout Span Set Use and to position the cursor under the desired char acter Then use and to increm...

Page 60: ...e expressed as a percent of the analog output span used by the meter as a TEST signal 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 User Aout Use the and keys to select Test and press ENTER Zero Setpoint Span Setpoint Test POWER ESC ENTER User Aout Aout ...

Page 61: ... trim The meter now automatically returns to the Analog Output prompt Using the procedure under Testing the Analog Output on page 4 21 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 User Aout Use the and keys to select Zero Trim and press ENTER Span Setpoint Test Zero Trim PO...

Page 62: ... span trim The meter now automatically returns to the Analog Output prompt Using the procedure under Testing the Analog Output on page 4 21 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 User Aout Use the and keys to select Span Trim and press ENTER Test Zero Trim Span Trim P...

Page 63: ...ram or proceed to the appropriate section of this chapter to continue programming the analyzer Cfg Cal Opt Disp Use the and keys to select Opt and press ENTER POWER ESC ENTER Cfg Cal Opt Disp A list of the available options is shown Use the and keys to select User and press ENTER User Setup Lock Menus POWER ESC ENTER Cfg Cal Opt Disp A list of the available options is shown Use the and keys to sel...

Page 64: ...pad activity is detected This completes the adjusting of the display backlight Either press ESC until you exit the User Program or continue programming Cfg Cal Opt Disp Use the and keys to select Opt Then Use the and keys to select User and press ENTER User Setup Lock Menus POWER ESC ENTER User Use the and keys to select Backlight and press ENTER Analog Output Contrast Backlight POWER ESC ENTER Us...

Page 65: ...00 19200 38400 57600 or 115200 Cfg Cal Opt Disp Use the and keys to select Opt Then Use the and keys to select User and press ENTER User Setup Lock Menus POWER ESC ENTER User Use the and keys to select Comm and press ENTER Note The Fault Alarm and Analog Output options are also available in this list box Contrast Backlight Comm POWER ESC ENTER User Node ID Use the and keys to scroll the list of av...

Page 66: ...rial 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 Node I Data Length Use the and keys to select the desired data length and press ENTER 7 8 POWER ESC ENTER Node ID Bau Parity Use the and keys to select...

Page 67: ...s follows Note The Lock All and Versions options also appear in the above list box 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 Note The Erase Main option is also available in the above list box Cfg Cal Opt Disp Use the and keys to select Opt and press ENTER POWER ESC ENTER Cfg Cal Opt Disp Use th...

Page 68: ...ure to add or remove additional option cards Caution Be careful when using Erase Slot or Erase Main to make sure the information is no longer needed Setup Load Slot Use the and keys to select the desired slot designa tion and press ENTER 1 Load 2 Load POWER ESC ENTER ID Using a personal computer enter the appropriate informa tion Size Received Block Write to Slot 1 POWER ESC ENTER www DataSheet4U ...

Page 69: ... 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 t...

Page 70: ...y CO is not recommended since the analyzer will not respond correctly to dry calibration gases that do not contain H2 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 ...

Page 71: ...3 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 O2 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 ...

Page 72: ...gured 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 Note While in the User Program press ESC at any time to abort the current operation 1 Oxygen Press ESC to access the User Program The value shown indicates a 1 0 calibration e...

Page 73: ...m POWER ESC ENTER Setup Cal Diag Use the and keys to select Heater and press ENTER Heater POWER ESC ENTER PPM Percent Use the and keys to select PPM and press ENTER PPM Percent POWER ESC ENTER PPM Percent PPM Using the and keys position the cursor under the desired character Then use the and keys to incre ment the value When done press ENTER PPM 000 00 s POWER ESC ENTER PPM Invalid Output Use the ...

Page 74: ...service PPM Percent Cal Gas When ready use the and keys to select Next and press ENTER Start the Calibration Gas Back Next Cancel POWER ESC ENTER PPM Per Cal Heater This message appears until the calibration adjustment has been completed usually about 15 30 minutes Calibrating Heater S xxx T xxx x D xx x Back Cancel POWER ESC ENTER If the calibration passed use the and keys to select Finish and pr...

Page 75: ...to abort the current operation 1 Oxygen Press ESC to access the User Program see page 4 1 2 71 ppm POWER ESC ENTER Cfg Cal Opt Disp Use the and keys to select Cal and press ENTER POWER ESC ENTER Cfg Cal Opt Disp A list of the slots available for calibration is shown Use the and keys to select 1 Cal and press ENTER 1 Cal 2 Cal POWER ESC ENTER Setup Cal Diag Use the and keys to select Diag and press...

Page 76: ...l 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 Setup Cal Diag Use the and keys to select Impedance and press ENTER Impedance View Temp Controls POWER ESC ENTER Sensor Impedance The oxygen sensor impedance in ohms is shown Press ENTER to continue Impedan...

Page 77: ...Chapter 5 www DataSheet4U com www DataSheet4U com ...

Page 78: ...Service and Maintenance Introduction 5 1 General Troubleshooting 5 1 Calibration Responses 5 11 Parts Replacement 5 12 Recommended Spare Parts 5 24 www DataSheet4U com www DataSheet4U com ...

Page 79: ... 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 General Troubleshooting This section discusses the following general ca...

Page 80: ...allation and the wiring diagram in Figure 2 2 on page 2 10 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 5 2 on page 5 25 and short them together with a jumper The oxygen display should read 20 93 Note Due to an uncorrected offset in s...

Page 81: ...of the conditions listed in Table 5 1 below should occur 3 Complete the action recommended in Table 5 1 above Note If a voltage reading other than those listed above is obtained refer to Figure 5 1 and or Table 5 2 on page 5 4 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 1 above proceed...

Page 82: ...3 600 24 1073 760 30 8296 610 24 5322 770 31 2429 620 24 9566 780 31 6553 630 25 3805 790 32 0668 640 25 8039 800 32 4773 650 26 2267 850 34 5150 660 26 6489 900 36 5278 670 27 0705 950 38 5154 680 27 4914 1000 40 4775 690 27 9115 1050 42 4131 700 28 3309 1100 44 3206 710 28 7494 1150 46 1973 720 29 1672 1200 48 0401 500 600 700 800 900 1000 1100 1200 TEMPERATURE C 20 25 30 35 40 45 50 VOLTAGE mV ...

Page 83: ...ating temperature was too low the troubleshooting sequence should resume here Note For information regarding component locations and or 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 ...

Page 84: ...2 2 on page 2 10 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 If the 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 5 4 above proceed to the appropriate section for instructions If the...

Page 85: ...usual 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 IMPORTANT This symbol indicates Caution dangerously hot surfaces Checking the Oxygen Sensor Wirin...

Page 86: ... 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 the factory for assistance Caution Do not tighten fittings more than 1 8 turn at a time Checking the Digital Display If the shorted wiring and plumbing leak checks have not corrected t...

Page 87: ...libration 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 H2 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...

Page 88: ... 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 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 reading will be higher than expected Proceed as follows The easiest way ...

Page 89: ...on proper installation of the analyzer 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 inle...

Page 90: ...by step instructions in this section Note For information regarding component locations and or wiring connections in an optional enclosure see Appendix C Caution If the 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 procedur...

Page 91: ... could result Always wear heat resistant gloves while performing these procedures IMPORTANT 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 power...

Page 92: ...ions and or 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 5 Strip 1 2 of insulation off th...

Page 93: ...emove the defective oxygen sensor assembly proceed as follows 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 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 5 2 on page 5 25...

Page 94: ...the old assembly Caution If the 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 2 Secure the mounting plate to the bottom of the enclosure with the four screws previously removed 3 Reinstall the upper and lower clips onto the oxygen sensor body 4 Connect the inlet and outlet...

Page 95: ...tively 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 cut 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 enclos...

Page 96: ...gen 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 7 Energize the main power to the meter and calibrate the oxygen sensor see Calibrating the Model CGA 351 on page 4 31 This completes the replacement of the thermocouple Replacing the Sensor Furnace The se...

Page 97: ...ce 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 terminal screws from the ceramic power block 6 Carefully remove the two...

Page 98: ...nnect the main power to the unit and recalibrate the oxygen sensor see Calibrating the Model CGA 351 on page 4 31 This completes the replacement of the sensor furnace 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 procedure...

Page 99: ...ternal 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 2 2 on page 2 10 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 correct fuse to use 5 Install t...

Page 100: ...g 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 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 enclosure and secure it...

Page 101: ...ding will result in serious personal injury 2 Remove the panel meter as described in the previous section see page 5 22 3 Remove the defective controller card from Slot 1 of the panel meter and install the new controller card in its place 4 Reinstall the panel meter into the electronics enclosure as described in the previous section above 5 Reconnect the main power to the analyzer 6 Refer to Chapt...

Page 102: ... enclosure as described in a previous section see page 5 22 5 Reconnect the main power to the analyzer 6 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 Recommended Spare Parts Table 5 5 Spare Parts List CGA 351 Part Number Qty Description 1214 510 2 Outer Oxygen Sensor Clip 238 085 1 ...

Page 103: ...unting Plate bottom view Outlet Fitting Inlet Fitting Mounting Screw 6 pl Inlet Fitting Mounting Plate Manifold Fitting Nut Oxygen Sensor Ceramic Block Mounting Holes Thermocouple Mounting Bracket Mounting Screw Sensor Upper Clip Sensor Lower Clip A A Sensor Furnace bottom www DataSheet4U com www DataSheet4U com ...

Page 104: ...Chapter 6 www DataSheet4U com www DataSheet4U com ...

Page 105: ...Specifications General Specifications 6 1 Operating Specifications 6 2 Ordering Information 6 3 www DataSheet4U com www DataSheet4U com ...

Page 106: ...onth Operating Temperature Typical 700 C Maximum 950 C Ambient Temperature Influence no effect Atmospheric Pressure Influence no effect if sampling gas is vented to atmosphere otherwise 0 13 of reading per mm of Hg Sample Flow Rate Influence no effect if sample flow rate 1 000 150 cc min 2 1 0 3 SCFH Line Voltage Influence no effect on sensor output Background Gas Variation Effect no effect if sam...

Page 107: ... 25 to 50 C 13 to 122 F Power Requirements 110 115 or 220 230 VAC 50 60 Hz 250 W max Fuse 110 115 VAC 3 A 250 V 5x20 mm anti surge 220 230 VAC 1 1 2 A 250 V 5x20 mm anti surge European Compliance This unit complies with EMC Directive 89 336 EEC 73 23 EEC Low Voltage Directive Installation Category II Pollution Degree 2 and Pressure Equipment Directive 97 23 EC in accordance with Article 3 Paragrap...

Page 108: ...rom the options specified B C D CGA351 Table 6 1 CGA351 Oxygen Analyzer Ordering Information LTR CATEGORY OPTIONS B Voltage 1 100 VAC 2 115 VAC 3 220 VAC 4 240 VAC C Package 1 Standard Design on wall mount plate 2 Rack Mount D Inlet Outlet Tube Fitting 1 1 4 inch tube fitting 2 6mm tube fitting www DataSheet4U com www DataSheet4U com ...

Page 109: ...Appendix A www DataSheet4U com www DataSheet4U com ...

Page 110: ...The Nernst Equation Introduction A 1 Equilibrium Conditions A 1 The Model CGA 351 Nernst Equation A 2 www DataSheet4U com www DataSheet4U com ...

Page 111: ...ection thus tending to oppose further diffusion 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...

Page 112: ...arizer 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 zirconia oxygen analyzer Equation A 3 above has been converted into a graphical format Use this graph see Figure ...

Page 113: ... Sensor Output at 700 C Oxygen Concentration 100 10 1 0 1 0 01 0 001 0 0001 Sensor Output mV at 700 C 50 0 50 100 150 200 250 300 0 00001 1 000 000 ppm 10 000 ppm 100 000 ppm 1000 ppm 10 ppm 100 ppm 1 ppm 0 1 ppm 350 www DataSheet4U com www DataSheet4U com ...

Page 114: ...3 964 8 3 212 483 1 4 249 795 4 9 223 532 8 4 212 232 1 5 248 349 5 0 223 108 8 5 211 984 1 5 246 996 5 1 222 693 8 6 211 738 1 7 245 725 5 2 222 286 8 7 211 496 1 8 244 527 5 3 221 887 8 8 211 256 1 9 243 393 5 4 221 495 8 9 211 020 2 0 242 318 5 5 221 110 9 0 210 785 2 1 241 295 5 6 220 732 9 1 210 554 2 2 240 320 5 7 220 361 9 2 210 325 2 3 239 388 5 8 219 997 9 3 210 098 2 4 238 496 5 9 219 63...

Page 115: ...Appendix B www DataSheet4U com www DataSheet4U com ...

Page 116: ...CE Mark Compliance Overview B 1 EMC Compliance B 1 LVD Compliance B 1 www DataSheet4U com www DataSheet4U com ...

Page 117: ...ires 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 CGA 351 Note If the instructions in this appendix are followed the unit will comply with the Low Voltage Directive 73 23 EEC Table B 1 Wiring Modifications for EMC Compliance Connection Wiring Modification...

Page 118: ...Appendix C www DataSheet4U com www DataSheet4U com ...

Page 119: ...Optional Enclosures Introduction C 1 Rack Mount Installation C 1 Rack Mount Operation C 4 Rack Mount Service and Maintenance C 4 www DataSheet4U com www DataSheet4U com ...

Page 120: ...nstallation The CGA 351 analyzer is available in a rack mount enclosure for installation in a standard 19 electronics rack see Figure C 1 below Figure C 1 CGA 351 Rack Mount Version Mounting the Rack Mount Refer to Figure C 5 on page C 6 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 ...

Page 121: ... factory The sample system would be supplied fully assembled on a flat plate with four 4 mounting holes Figure C 2 CGA 351 Rack Mount Version Rear Panel Wiring the Rack Mount 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...

Page 122: ...ut wire to the external device to pin b Connect the output wire from the external device to pin 3 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 4 Connect any shields to pin G Figure C 3 Terminal Block Con...

Page 123: ...enclosure Proceed to Chapter 3 Operation and Chapter 4 Setup and Calibration for instructions on using the meter 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 ...

Page 124: ...edle nose pliers pull each of the two fuse holders with an arrow printed on the end straight out of the unit 4 Replace the fuses with new ones of the same type and rating See Chapter 6 Specifications for the correct fuse to use 5 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 Figure C 4 Ra...

Page 125: ...igure C 5 CGA 351 Rack Mount Version Outline and Mounting Dimensions Dimensions are in inches millimeters 17 15 436 18 44 468 7 00 178 18 25 464 0 90 23 5 25 133 19 00 483 19 78 502 18 67 474 6 75 171 www DataSheet4U com www DataSheet4U com ...

Page 126: ... Normally Open Standard Mode Common Normally Closed Failsafe Mode TB1 OUTPUTS HEATER TC Thermocouple Furnace Any Gnd Shield 1 2 Furnace G G Any Gnd Shield Thermocouple O2 Group Description TB2 INPUTS Pin Sensor Sensor ALL ALL 6 White 5 White N A G White N A Red N A Yellow 2 White 1 White Wire Color G TB3 POWER N L Pin 90 265 VAC 50 60 Hz 250 W NOTE For proper operation the unit must be powered by ...

Page 127: ...ck Mount Version Major Components WARNING Hot surfaces Zirconia Oxygen Analyzer Output Terminal Block Sample Meter Bypass Meter Digital Panel Meter Main Printed Circuit Board Gas Fittings Sensor Enclosure see Figure 5 2 www DataSheet4U com www DataSheet4U com ...

Page 128: ...rt Name Contrast Adjusting 4 24 Controller Card Replacing 5 23 Converting mV to ppm 3 8 A 4 D Data Bits 4 27 Dead Space 5 11 Diagnostic Menu 4 36 Digital Display Backlight Setting 4 25 Components 3 3 Configuring 3 3 Contrast Adjusting 4 24 Multiple Windows 3 6 Output Devices 3 5 Parameters 3 5 Replacing 5 22 Testing 5 8 Disconnect Device 2 1 2 3 Display See Digital Display E EMC Compliance B 1 Enc...

Page 129: ... A 1 Graphical Form A 2 Numeric Form A 1 Node ID 4 26 O Option Card Slots Setting Up 4 28 Option Card Replacing 5 24 Ordering Information 6 3 Oxygen Errors 5 7 Oxygen Sensor See Sensor P Parity 4 27 PID Heater Control 1 6 Plumbing Leaks 5 8 5 10 Power Requirements 6 2 Powering Up 3 2 Proportional Band 1 6 4 11 R Rack Mount Version C 1 Range Outputs 6 2 Percent Oxygen 6 2 Recovery Time 5 11 Replaci...

Page 130: ...5 24 Specifications General 6 1 Operating 6 2 Stop Bits 4 27 T Temperature Ambient 2 1 Controls Default 4 14 Controls Setting 4 8 Minimum 1 4 Operating 6 1 Set Point 4 9 4 10 Typical 1 4 Terminal Block TB1 2 6 TB2 2 7 TB3 2 8 Thermocouple Description 1 2 Replacing 5 17 Testing 5 3 Voltage vs Temperature 5 4 Wiring 2 7 Troubleshooting Diagnostic Menu 4 36 Digital Display 5 8 Furnace 5 5 Overview 5 ...

Page 131: ... 61326 1998 Class A Annex A Continuous Unmonitored Operation EN 61010 1 1993 A2 1995 Overvoltage Category II Pollution Degree 2 following the provisions of the 89 336 EEC EMC Directive and the 73 23 EEC Low Voltage Directive The units listed above and any sensors and ancillary sample handling systems supplied with them do not bear CE marking for the Pressure Equipment Directive as they are supplie...

Page 132: ...d Operation EN 61010 1 1993 A2 1995 Overvoltage Category II Pollution Degree 2 suivant les régles de la Directive de Compatibilité Electromagnétique 89 336 EEC et de la Directive Basse Tension 73 23 EEC Les matériels listés ci dessus ainsi que les capteurs et les systèmes d échantillonnages pouvant être livrés avec ne portent pas le marquage CE de la directive des équipements sous pression car ils...

Page 133: ...998 Class A Annex A Continuous Unmonitored Operation EN 61010 1 1993 A2 1995 Overvoltage Category II Pollution Degree 2 gemäß den Europäischen Richtlinien Niederspannungsrichtlinie Nr 73 23 EG und EMV Richtlinie Nr 89 336 EG Die oben aufgeführten Geräte und zugehörige mitgelieferte Sensoren und Handhabungssysteme tragen keine CE Kennzeichnung gemäß der Druckgeräte Richtlinie da sie in Übereinstimm...

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