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Manual

GA-21Plus

1. INTRODUCTION

Congratulations on your purchase of the microprocessor-controlled flue gas ana-

lyser

GA-21

plus

It is a high quality instrument produced using the latest technical discoveries. The

GA-21

plus

is easy to use. You also have the possibility of using the extra capabilities of

this analyser, of examining measurement results, checking service intervals and many

others. Please read the operating manual carefully. It contains valuable tips and informa -

tion for problem-free operation. Regular maintenance will help to keep your analyser

ready for use at all times.

1.1. Use of this operating manual

Keep this manual with the analyser

GA-21

plus

and take it with you when carry-

ing out measurements. Here is a short description of the sections of this manual.

2. Maintenance

This section contains important information designed to keep your analyser work-

ing and to save you time and trouble.

3. General information

This describes the most important characteristics of your new analyser.

4. Construction

A knowledge of the hardware of the analyser will help you to use the instrument

correctly and to avoid unnecessary down-time.

5. Operation

This section explains the use of the analyser with detailed descriptions of the vari-

ous functions. It is important to read the sections

5.1

and

5.2

first. The other sections can

be read when required.

Summary of Contents for GA-21 plus

Page 1: ...FLUE GAS ANALYSER GA 21 plus Operating manual Version 2 0 04 2013 ...

Page 2: ...4 2 5 Differentia pressure sensor 12 4 2 6 Analogue inputs 12 4 3 Data input output system 14 4 3 1 Keyboard 14 4 3 2 Display 16 4 3 3 Printer 16 4 3 4 Interface RS232C 16 4 3 5 Power supply 17 5 Operation 18 5 1 Use of the keyboard 18 5 1 1 Description of the keys 18 5 1 2 Selecting menu options 19 5 1 3 Entering numbers 20 5 1 4 Editing text 20 5 2 Basic operating instructions 21 5 2 1 Setting u...

Page 3: ...ck 44 5 6 3 4 Printer 45 5 6 3 5 Language Country 46 5 6 3 6 Acoustic warning 46 5 6 3 7 Soot 1 3 46 5 6 3 8 Standard 46 5 6 4 Control list 47 5 6 5 madur Service 47 5 7 Storing of results 48 5 7 1 Storing measurement reports 49 5 7 1 1 Report table 50 5 7 1 2 Header Notice editing 52 5 7 1 3 Erasing reports 53 5 7 2 Continuous storing of results 53 5 7 2 1 Banks table 55 5 7 2 2 Erasing banks 55 ...

Page 4: ...use at all times 1 1 Use of this operating manual Keep this manual with the analyser GA 21 plus and take it with you when carry ing out measurements Here is a short description of the sections of this manual 2 Maintenance This section contains important information designed to keep your analyser work ing and to save you time and trouble 3 General information This describes the most important chara...

Page 5: ...rged do not switch the analyser off before the system is purged of remaining flue gas store the analyser in a cool place to reduce the ageing of the cells 2 2 Gas system The gas system of the analyser is protected by a double in line filter The ele ments should be changed when necessary Check the condensate traps regularly and empty them when needed 2 3 Battery The rechargeable battery used in the...

Page 6: ...IST 2 6 Switching off after use The operating life of the electrochemical cells is dependent on the usage of the instrument The wear and tear on the cells is greater when the cell is exposed to the gas for longer or the concentration is higher The gas cell is hence used up during measure ments Info For this reason the analyser should not be switched off until all the gas tubing has been completely...

Page 7: ...alysers are fitted with O2 and CO sensors fur ther gas cells must be chosen when the instrument is ordered The following description is based on an analyser containing 3 cells the third one being an NO sensor Oxygen O2 Carbon monoxide CO Nitric oxide NO Carbon dioxide CO2 Nitrogen oxides NOx The first three gases O2 CO NO are measured directly using the electrochem ical cells The remaining compone...

Page 8: ... 21 plus is ideally suited for all those involved in the construction maintenance and adjusting of heating systems The keyboard of the instrument can be wiped clean if necessary The GA 21 plus is controlled by a microprocessor The easy to read LCD dis play the comprehensive keyboard and the built in printer allow the operator to communic ate with the instrument easily and to document the measureme...

Page 9: ...cally supplies in one of four standard lengths 150 mm 300 mm 450mm 750 mm 1000mm and 1500 mm As standard a Ni CrNi thermocouple is used The probe pipe is fitted with an anchor cone to simplify fixation in the flue gas chan nel The probe pipe is attached to the probe holder with a threaded connector The gas tubing in the GA 21 plus is protected from the dust and moisture present in the flue gases b...

Page 10: ...Oxygen and carbon monoxide cells are standard equipment The other sensors are chosen when the instrument is ordered The gas chamber of the GA 21 plus system is characterised by minimal dead capacity which leads to low inertia of the analyser indica tions In addition to the gas sensors there is a temperature sensor placed in the chamber for temperature compensation of the sensors 4 2 Measurement sy...

Page 11: ... the sensor should not be ex ceeded all the gas sensors can react unpredictably to certain chemicals which are not typical for combustion gas composition For this reason it is absolutely forbidden to wash the parts of the gas line with chemical solvents The vapours from such solvents can get inside the gas chamber and result in destabilisation or even permanent damage of the gas sensors the gas se...

Page 12: ...range up to 1600oC Proper flue gas temperature measurement is the most important factor for correct calculation of the chimney loss and other heat engineering results 4 2 4 Gas chamber temperature sensor To compensate for temperature drift of the gas cells the temperature of the gas chamber is constantly monitored 4 2 5 Differentia pressure sensor The GA 21 plus is fitted with a precise semiconduc...

Page 13: ... view outputs optional 1 GND 2 I1 in 3 U1 in 4 I1 out GND optional 5 I1 out 0 4 20mA optional Parameter U I Range 10V to 10V 10mA to 10mA Input resistance 100kΩ 100Ω Resolution 10mV 10µA Temperature input top view 1 PT3 Thermistor 1 2 TH1 Thermocouple 1 3 GND 13 ...

Page 14: ...ys are modern membrane keys with per ceptible stroke Each press of a key is accompanied by an acoustic signal The keyboard is shown in picture B page 14 and consists of the following elements PROBE Socket for the electrical connection of the probe holder GAS Connector for the gas hose PRESSURE Connectors for the differential pressure sensor RS 232 C Socket for the RS232C cable TEMP 1 Socket for th...

Page 15: ...www madur com Manual GA 21Plus Picture 2 Front elevation picture 15 ...

Page 16: ...ot matrix printer capable of printing the data as graphic or in the form of tables All the screens seen on the analyser may be prin ted Printing speed is about 2 5 lines per second The printer uses normal paper 57 mm wide 4 3 4 Interface RS232C The GA 21 plus is fitted with a serial RS232C interface The socket is mounted on the front of the instrument and marked RS232C The interface allows the GA ...

Page 17: ...n and supplied from the battery Mains supply not present Green analyser switched off and mains supply present The battery is char ging Orange analyser switched on and mains supply present The battery is char ging The maintenance free 12 V battery has a capacity of 2 Ah A fully charged battery will power the instrument for about five hours When the battery voltage drops below 11 V three acoustic wa...

Page 18: ...s to Alphanumeric keyboard for entering data and for fast movement between MENU options Decimal point when entering data If used when the screen is showing RESULTS this key switches the zoom function on or off starts a print out moves the paper forward one line switches the analyser on switches the analyser to stand by or off moves one step backwards in the menu moves one step forward in the menu ...

Page 19: ...rds in the menu if the cursor is on the right side of the Option line or the Title line the key leads to the displayed Option executes the displayed function starts data storage for example in the Command line starts or ends the respective edit function setting the average time for example in the Data line switches i e YES NO in the Switch line to for fast movement between MENU options If a displa...

Page 20: ... it has the shape of an underlining and move the cursor within the line erases the whole text line to the alphanumeric keys enter numbers in digital mode or letters in alphabetical mode Each key has a three letter designation The first press enters the first letter the next presses the second and the third letter Key presses in alphabetical mode does not move the cursor SPACE prints 0 number in di...

Page 21: ...ose from the filter to the connector INLET Ensure that the gas flow from the base of the analyser is free of ob structions 5 2 2 Switching on Before use the condition of the analyser should be checked Check the filter elements Clean or replace as necessary Check the state of charge of the battery if the analyser is to be operated from the internal battery This is carried out by switching on and re...

Page 22: ...oncentration detec ted in the gas chamber In this case the instrument will automatically switch to FLOODING WITH AMBIENT AIR mode and switch to STANDBY mode later on The following screen is shown in the STANDBY mode By pressing OFF the instrument can be switched off completely If C is pressed the instrument switches ON again If the instrument is in STANDBY mode for more than 8 5 hours it switches ...

Page 23: ...utes Warning Make sure the probe is not in the stack during the initial calib ration Initial calibration is of basic importance for measurement correctness and it must not be interrupted before it is finished automatically During this time the Oxygen sensor is calibrated to 20 95 in ambient air and the other sensors CO NO will be zeroed 23 ...

Page 24: ...e calibration is finished the option PARAMETER is displayed for control reasons or in case changes need to be done Usually the option is selected as fol lows selects the MENU screen and move the cursor to the PARAMETER option select the option The following screen will appear 24 ...

Page 25: ...the selection of a fuel if necessary or the programming of a customised fuel From PARAMETER you move to the option as follows and move the cursor to FUEL choose SELECT FUEL and move the cursor to the desired fuel confirm the selection an asterix will apear on the left side 25 ...

Page 26: ...L The following screen appears The already defined fuels can only be viewed For the user definable fuels all parameters can be programmed The variables are as follows 0000000000 Name of the fuel DP CO2max the maximum concentration of CO2 for complete combustion O2 0 A1 B factors for Siegert s formula ALPHA fuel specific parameter O2R reference oxygen Vgd volume of the flue gas at perfect combustio...

Page 27: ... 1 to 60 confirm the number and select min or sec confirm the selection 5 2 5 3 Reference oxygen parameters O2R To select the reference oxygen proceed as follows and move the cursor to O2R switches between a pre programmed standard value NORM and a free programmable one called manual value to if manual was selected a number from 1 to 20 can be entered confirms and ends editing 27 ...

Page 28: ...t documentation and move the cursor to BOILER PARAMETER select with YES NO whether or not the Boiler Para meters shall appear on the printout respectively be ing stored in a Protocol if YES was selected this key moves to the Boiler Parameter menu The boiler parameters can be entered in the screen shown below Boiler power Boiler consumption Boiler temperature 28 ...

Page 29: ...ement results Select the measurement screen by pressing DATA The measurement results are displayed on three screens either as current values or as averaged values 5 3 1 Current values select the first screen and move backward or forward to select a screen 29 ...

Page 30: ...o select one of four screens switches between AVERAGED VALUES and CUR RENT VALUES the display on the AVERAGED VALUE screen gets synchronised a row of strokes appears instead of the values and a new averaging session starts The meas ured results are displayed after the whole cycle is finished switches On Off the HOLD function freezing the current values Warning If a continuous storage recording is ...

Page 31: ...would be shown on the display During the start of the averaging process a row of strokes appears on the screen since there are no results to display If measurement parameters are changed during the averaging process the aver aging cycle has to be re started In case the data storage is activated it is stopped as well The following incidents cause an interruption of the averaging cycle change of the...

Page 32: ...erature are displayed on the screen The last line shows the command ZEROING By pressing this key the sensor is set to zero e g the current value will be taken as zero value Please be aware that the sensor has to be zeroed before the measurement ZEROING the sensor Connect end of the sample hose to the PRESSURE stub The screen will dis play the measured pressure and the measured gas temperature leav...

Page 33: ...he instrument is connected to the mains The soot test is done by means of the Bacharach comparison method select the main MENU and move the cursor to SOOT TEST select the option the pump is switched off and the following screen appears Insert the soot filter in the slit of the heated probe holder and place the probe in the stack starts the soot measurement The pump is switched on and sucks in 60 s...

Page 34: ...to enter the detected soot number confirm the soot number The stored soot number remains stored until a new one is entered or either a printout of the measured values is performed or they are stored in a report 5 6 Options The OPTIONS can be reached from the MENU as follows and move the cursor to OPTIONS select option The following screen appears 34 ...

Page 35: ...ion The DEVICE INFO screen shows the serial no of the instrument the date of the last service the operating time the time until the next service the speed of the sucked flue gas the battery charge the battery capacity and whether or not the communication with the madCom PC software is locked 35 ...

Page 36: ...esults collected using low concentration CO sensor When the meas ured gas concentration exceeds value inserted in CO C range then the purging pump starts flushing the low concentration CO sensor with ambient air for its protection Result are from this point collected using high concentration CO sensor When the gas concentration drops be low value inserted in CO C range then the pugging pump stops ...

Page 37: ...CO RANGE start editing of the value to enter a number between 0 and 20000 ppm close the option 5 6 2 3 O2 cell calibration To increase the accuracy of the O2 sensor during measurements over a longer period of time the GA 21 plus has the capability of calibrating the sensor with ambient air Take the probe out of the stack and move the cursor to O2 cell calibration select the option The following sc...

Page 38: ... temperatures up to 1600 C the setting can be changed to PtRh Pt thermocouple Of course that would need the use of the respective thermocouple as well Pt AMB Ambient temperature sensor default setting Pt 500 The ambient temperature can either be measured with an internal sensor placed in the probe plug Pt500 or with an external sensor Pt500 connected to the TEMP T3 EXT socket T1 T2 EXT External th...

Page 39: ...sensor The input T3 EXT can be defined as a Pt100 Pt500 or KTY 2k thermistor U I1 EXT External Voltage Current input Select the desired input sig nal The socket U I1 can be used to measure either current 0 10 mA or voltage 10V 10V U I2 EXT External Voltage Current input second current or voltage in put 39 ...

Page 40: ...nge is followed by loss of the original cal ibration settings Thus the CALIBRATION option should be selected only when it is to be carried out The standard gas concentration should be similar to that usually met during measurement and it should not be less than 10 of the required measuring range of a given sensor The time the sensor is fed with standard gas should not be less than 4 min After each...

Page 41: ... currently installed electrochmical sensors are visible in this screen The individual rows have the following meanings Cell Sensor type Signal Curent sensor s signal value Stored Stored signal value in the GAS ppm line starts editing of the standard gas concentration to enter the concentration of the standard gas ppm in the line GAS 41 ...

Page 42: ...strument with standard gas for about 4 min in the STORE line as soon as the value has stabil ised stores the measured value as calibration value Disconnect the standard gas and flood the instru ment for at least 15 min with ambient air return to select the next gas or end the calibration 42 ...

Page 43: ...e of the standard settings and move the cursor to the option SETTINGS select the option 5 6 3 1 Backlighting pressing the key switches the BACKLIGHTING on and off 5 6 3 2 Contrast and move the cursor to CONTRAST select option Follow the explanations on the screen to adjust the contrast 43 ...

Page 44: ...ows the internal clock to be adjusted and move the cursor to CLOCK select option and move the cursor to desired line opens editing to set date and time They are entered in the sequence TIME HH MM SS and DATE as given by the format line below confirms settings 44 ...

Page 45: ...eport will still have all the information as usual AUTO PRINTING switches between YES NO If the option is activ ated automatic printouts will be carried out ac cording to the programmed average time provided the time is not less than 2 min If the av erage time is shorter than 2 min only one prin tout will be performed No OF COPIES switches between 1 2 3 FOOTER No the instrument can store up to 50 ...

Page 46: ...bles the user to select between languages and move the cursor to LANGUAGE confirms the selection and select language confirms the language 5 6 3 6 Acoustic warning enables deisables acoustic warning 5 6 3 7 Soot 1 3 5 6 3 8 Standard sets the instrument to default settings 46 ...

Page 47: ...s a similar list to the one above The list shows which subassembly functions correctly OK or which is defective E and move the cursor to CONTROL LIST select option 5 6 5 madur Service This option is for service engineers only A code is needed to enter the menu exit with MENU key 47 ...

Page 48: ...be stored in two separate forms Up to 30 measurement reports and up to 10 banks from continuous measurements containing a total of 1024 sets of results Using an averaging time of 30 minutes this would allow the results of over 21 days of measurements to be stored please be aware that for measuring sessions of that length a proper gas conditioning system is absolutely necessary selects the menu STO...

Page 49: ...rements must be carried out before storing the report The report will contain either the current or the averaged results depending on which screen was vis ible when the storing process was started Store REPORTS as follows the measured values are displayed Do you want to print the displayed valuesproceed as follows select option The measured values are stored in a buffer memory and move the cursor ...

Page 50: ...table This option allows one to view print and erase Report contents and move the cursor to REPORTS TABLE select option Reports without are empty erases the selected Reports shows the selected Reports the following screen REPORT NO XX is opened 50 ...

Page 51: ...www madur com Manual GA 21Plus 51 ...

Page 52: ... of 20 characters Measurement site and or short description of the site are commonly stored in such notes and move the cursor to HEADER EDITING select option The pictures show screens without text The screen appears as it was when the report was stored How the text should be edited is described in section 5 1 4 This screen can be left at any time using MENU and DATA 52 ...

Page 53: ... measurement session The EEPROM can store up to a total of 1024 blocks freely dividable between 10 measuring sessions These 10 sets of results are known as BANKS The size of a single bank is only limited by the free memory available Each bank also contains all necessary information about the measure ment fuel time O2R averaging time etc All the results stored are average results for the time set I...

Page 54: ...TE ALL BANKS can be used and move the cursor to the option BANKS open the option BANKS and move the cursor to the line STORAGE Set or check the averaging time start the storing the word ACTIVE appears the measured calculated values are shown storage is active Stopping the continuous storing of results call the STORE menu and move the cursor to the option BANKS open the option BANKS and move the cu...

Page 55: ...to the option BANKS TABLE select the option BANKS TABLE The last bank can be erased in the BANKS TABLE screen the Bank must not be active and move the cursor to the last stored Bank erase bank 5 7 2 2 Erasing banks The option DELETE ALL BANKS allows to erase all Banks and move the cursor to DELETE ALL BANKS select the option leaves the screen without erasing BANKS erases all BANKS 55 ...

Page 56: ...ue inputs can either be read from the DATA screen or be stored continuously in a bank The madCom software can then be used for further treatment of these results Warning The ground GND of all analogue inputs is connected to the in strument ground 5 9 Printer 5 9 1 Printing the contents of a screen This is not possible for the screen D1 A screen may not be printed whilst data is being entered using...

Page 57: ...www madur com Manual GA 21Plus 57 ...

Page 58: ... control sensor 5 Pressure sensor 6 Electrochemical cells in the main gas channel 7 Check valve 8 Purging pump 9 Electrochemical cell in the secondary gas channel 10 Gas outlet 1 11 Gas outlet 2 12 Differential pressure inlets for the duct s flow velocity measurement 13 Second pressure sensor 58 ...

Page 59: ...test Soot test Options Device info View data Sensors CO range O2 cell calibr Calibrate External channels Choose input TH Gas PT Amb T1ext T3ext U I1 Calibration w gas Choose cell Calibrate CO2 zero Settings Backlighting Contrast Set contrast Clock Set date time Printer settings Shortform Automatic printing No of copies Choose footer Language country Language Standard Control list Service ...

Page 60: ...l GA 21Plus 7 2 Structure of the menu STORE STORE Reports Save Report No Reports Table View Report Header Editing Edit Banks Activate Lock List of Banks View List Delete All Reports Erase All Delete All Banks Erase All 60 ...

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