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PGA 3510 

Portable Multi-Gas IR Analyzer 

(CO, CO

2

, and CH

4

 Gas Analyzer 

with O

2

 and Optional H

2

 Measurement and  

% Carbon, % Dissociated Ammonia, % NH

3

, K

N

, and 

K

C

 Calculation Capabilities) 

 

Operations Manual 

 

 

 

 

Please read, understand, and follow these instructions before operating this equipment. 

Super Systems, Inc. is not responsible for damages incurred due to a failure to comply with these 

instructions.  If at any time there are questions regarding the proper use of this analyzer, please contact 

us at (513) 772-0060 for assistance. 

 

 

 

Summary of Contents for PGA 3510

Page 1: ...ation Capabilities Operations Manual Please read understand and follow these instructions before operating this equipment Super Systems Inc is not responsible for damages incurred due to a failure to comply with these instructions If at any time there are questions regarding the proper use of this analyzer please contact us at 513 772 0060 for assistance ...

Page 2: ...ands B75 7BU UNITED KINGDOM Phone 44 0 121 329 2627 http www supersystemseurope com Super Systems México Sistemas Superiores Integrales S de RL de CV Calle 3 Int 11 Zona Ind Benito Juarez Querétaro Qro Méx C P 76120 Phone 52 442 210 2459 http www supersystems com mx Super Systems China No 335 XianXia Road Room 308 Shanghai CHINA 200336 Phone 86 21 5206 5701 2 http www supersystems com Super System...

Page 3: ...Parameters 19 COF PF Adjustment Increment 20 COF PF Adjustment Interval minutes 20 Minimum COF PF Value 20 Maximum COF PF Value 20 COF PF Adjustment Mode 20 Communications and Source Setup 21 IP Address 21 Atmosphere Temp Sources 22 Port Setup 23 Instrument Setup 24 Calculation Factors 24 General Setup 30 Security Settings 30 Factory Default Settings 30 Other Settings 31 Language Setup 31 Instrume...

Page 4: ...ture of the measured gas For nitriding and ferritic nitrocarburizing FNC applications the PGA 3510 can calculate carburizing potential KC and nitriding potential KN Finally the PGA 3510 can be configured for compatibility with environments containing ammonia NH3 gas NH3 compatibility must be specifically requested when the PGA 3510 is ordered IMPORTANT Do not use a PGA 3510 for gas analysis with N...

Page 5: ...nge 0 00 to 30 00 CO2 range 0 000 to 2 000 CH4 range 0 00 to 15 00 O2 range 0 1 to 25 0 H2 range 0 00 to 100 Note These sensors have been optimized for use at the levels normally seen in an Endothermic atmosphere The ranges can be adjusted to fit other applications For information regarding modifications to the ranges shown above please contact Super Systems Sampling method Extraction by internal ...

Page 6: ...Power Source 12VDC rechargeable NiCd battery with Integral charger Communications Ethernet USB A USB B RS485 Modbus Data Storage Continuous automatic data logging Data Retrieval XGA Viewer Software included or on screen Operating Temperature 32 to 122 F 0 to 50 C External Dimensions Approx 16 H X 20 L X 8 D Weight Approx 28 lbs Unpacking the Device The following items should be included with the P...

Page 7: ...e power switch is turned off the PGA 3510 initiates a controlled shutdown procedure which takes about 15 seconds Following the controlled shutdown the instrument will completely turn off Hydrogen Cell Note For highest H2 accuracy it is recommended that the instrument be powered on for 60 minutes before measurements are taken Default Screen Once the PGA 3510 has successfully loaded its software the...

Page 8: ...een the pump has two possible modes On and Off Carbon Calculation The PGA 3510 determines the percent carbon in the sample gas using measured amounts of CO CO2 and CH4 along with the Furnace Temperature The Furnace Temperature is either entered by the user or obtained automatically from the Furnace Temperature Controller via RS 485 communications Additionally the carbon percentage measured by the ...

Page 9: ...un along the bottom of the screen The Trend Lines button will allow the user to select or de select the trend lines on the trend chart to display If the checkbox next to each trend line is checked then that trend line will be displayed The Datagrid View button will display a screen with the trend data in a grid format instead of with trend lines The trend data is shown in 1 minute intervals Clicki...

Page 10: ...he user will need to re select the option from the sub menu to zoom in again The Restore option will back out of any zoom options that have been performed and display the initial chart screen The Add Note option allows the operator to enter a note on the chart similar to writing on a paper chart The note is available when the chart is printed out using the utility software included with the Series...

Page 11: ...ble options depending on whether the Nitrider Calculation feature is installed Carbon Calculation Nitrider Calculation if installed Sessions and Instrument Information can be accessed by any users Additional menu items are available when an authorized user logs in using an appropriate Pass Code When the Supervisor Pass Code is entered default 1 the user will also be able to access the Pump Control...

Page 12: ...al Super Systems Inc Page 12 of 42 To see the full range of options available the user must use the Configuration Pass Code Default 2 This provides the user with all available options including calibration and setup functions ...

Page 13: ...nd measured values for CO CO2 CH4 O2 and H2 if the H2 sensor is installed The calculated value for C is also shown User provided flow values for N2 NH3 DA and CO2 are used by the PGA 3510 in performing calculations The flow values are visible on the right side of the Nitrider Calculation page To change a flow value simply tap on the blue field for that value A numeric entry page will appear allowi...

Page 14: ...owing for easy identification of viewing and recalling data These tags can include the name of the operator and the name of the equipment that is being measured The instrument has default values for each of these variables However it is highly recommended that the selections be modified so that data may be tagged in a way that is easily recognized For more information on how to set up these select...

Page 15: ... sorted with the newest entry at the top but they can be sorted by End Time Equipment Name or Operator Name by touching the header of each column To see the details of any session highlight it by touching it and then press Detail This will display a graphical representation of the data from the selected session For more information on navigating the Chart Screen see the Chart section of this manua...

Page 16: ...s On or Off Sensor Calibration SSi Recommends the following user calibration schedule for the PGA3510 If the device is used Then perform a calibration Daily Weekly Weekly Monthly Less than weekly Prior to use NOTE This does not refer to SSi Factory Calibration Factory Calibration should be performed annually and is described in more detail on pages 33 36 ...

Page 17: ... accuracy is required to know the exact composition of the gas in the cylinder The actual composition will be shown on the bottle when it is delivered When flowing calibration gas is into the analyzer turn the pump off The amount of flow from the gas cylinder should be approximately 1 5 SCFH at no pressure The gas cylinders will be under high pressure so it is recommended that a two stage regulato...

Page 18: ...rubber is designed to remove CO2 from ambient air Ambient air should not have a significant amount of CO or CH4 However it does have some CO2 in it Using the scrubber will result in the instrument measuring a gas with no CO CO2 or CH4 which is the function of a good zero gas Unfortunately depending on the environment where the calibration is being performed ambient air may contain trace amounts of...

Page 19: ...tion for the Oxygen sensor There is only a Span Calibration To perform a Span calibration Take the instrument to an office or outdoors where it will be in fresh air Press the Calibrate O2 button on the Sensor Calibration screen When the Oxygen Calibration screen is entered the pump automatically turns on When the Actual value stabilizes press the Start Calibration button This will make the Actual ...

Page 20: ... a frequent interval instead of making large changes at longer intervals This will prevent temporary changes in atmosphere from making dramatic adjustments to the COF PF Minimum COF PF Value As a safeguard the COF PF can be prevented from dropping below a certain point This point is the Minimum COF PF value Maximum COF PF Value The Maximum COF PF can also be entered as a safeguard COF PF Adjustmen...

Page 21: ...P Address 1 Log in to the PGA 3510 touch screen using the supervisor access code by default this code is 2 2 Access the Instrument Setup General Setup menu 3 Select Shut Down Software followed by Yes 4 The program will shut down and a Windows CE screen will appear 5 Click the Start menu in the lower left corner 6 Select Settings and then Network and Dial up Connections 7 Select CS89001 8 Select th...

Page 22: ... mV Instrument This is the make and model of the device that will be supplying the instrument with information on probe temperature probe millivolts and COF PF Possible choices are SSi AC20 SSI 9200 9205 Loop 1 Yokogawa UDP750 Honeywell UDC3300 Dualpro Loop 1 Modbus Dualpro Loop 2 Modbus Probe Temp mV Instrument Address This is the address of the atmosphere controller It can be directly entered us...

Page 23: ...ualpro Loop 1 Modbus Dualpro Loop 2 Modbus Furnace Temp Instrument Address This is the address of the furnace temperature instrument It can be directly entered using the numeric keypad on the touch screen Port Setup This page is used to set the parameters for the communications ports The factory default settings are shown below and they should not need to be changed by the operator ...

Page 24: ...ould only need to be changed once Any modifications to the default values will be saved in the instrument Calculation Factors In this menu there are two factors that will influence the calculation of carbon IR Shim Factor and CH4 Factor Each of these factors is incorporated in the equation used to calculate C they are described in ...

Page 25: ...t IR Shim Factor adjustment value It is not directly modifiable Three Methods of Carbon Calculation The PGA 3510 is able to calculate Carbon using one of three methods Default Settings IRF Matrix or Equipment Specific IRF Matrices 1 Default Settings This is the method used when Use IRF Matrix is set to False off The sample gas composition CO CO2 CH4 and temperature along with the programmed IR Shi...

Page 26: ...imits are 0 25 0 4 and 0 6 the following ranges will be evaluated in helping to determine the IR Shim Factor Less than 0 25 Atm 0 25 0 25 0 39 0 25 Atm 0 4 0 4 0 59 0 4 Atm 0 6 0 6 and higher 0 6 Atm 3 Configure up to 3 temperature limits Each temperature limit marks a boundary line within the matrix Temperature values above and below each limit will be evaluated in determining the IR Shim Factor ...

Page 27: ...le settings False default and True If Use IRF Matrix is set to False the IRF Adjustment Matrix will not be used and Default Settings will be applied If Use IRF Matrix is set to True the IRF Adjustment Matrix will be applied to the IR Shim Factor Equipment Specific IRF Matrices The PGA 3510 can be set up to use different IRF Adjustment Matrices based on the specific equipment whose gas composition ...

Page 28: ...the equipment Parameters are described in the IRF Adjustment Matrix section above 5 Click Save when finished editing parameters The IRF Matrix for this particular equipment is now set up When ready to start a Session for this piece of equipment 6 Open the Sessions menu from the main PGA 3510 menu 7 Using the Equipment Name drop down box select the piece of equipment for which you want to want to a...

Page 29: ...nace Setpoint must both be set to True for this option to work In addition the PGA 3510 must not be configured to communicate with slave instruments see the IMPORTANT box below An example of how this option is used can be given as follows Assume that in the IRF Matrix one of the range sets is 0 25 Atm 0 4 Temp 1200 with a corresponding IR Shim Factor of 135 Because this range set is set up in the ...

Page 30: ...1 Log in to the PGA 3510 touch screen using the supervisor access code by default this code is 2 2 Access the Instrument Setup General Setup menu 3 Select Shut Down Software followed by Yes 4 The program will shut down and a Windows CE screen will appear 5 Click the time in the lower right corner press the stylus in this corner if the time does not automatically appear 6 Set the time and date to t...

Page 31: ...uper Systems prior to shipment but can also be changed by making a selection from the drop down list For the language change to take effect the instrument must be powered off and then back on again Instrument Information These items cannot be modified they can only be viewed General Information This is information on the revision levels of various components of the instrument This can be valuable ...

Page 32: ...e entered here Each name needs to be associated with a specific Equipment Type so that database should be populated first Maintain Sessions The PGA 3510 is designed to delete the oldest files first in the event that the storage capacity has been exceeded It is also possible to delete old files manually by entering a date on this screen All files that were made before that date would be permanently...

Page 33: ... of any values that are determined by the PGA 3510 and it is only provided as a reference tool User Manual An electronic version of the User Manual is located within the instrument for ease of reference Set User Cal Load User Cal This feature allows the user to create new factory default calibration settings for the sensor Instead of reverting to the factory calibration values it can revert back t...

Page 34: ...ure that the selected input at the top of the screen is mV 3 Prepare the millivolt sourcing device This device should be capable of sourcing a specified raw voltage between 0 and 1 volt 4 Connect the copper wire from the millivolt device to the white input jack labeled CU uncompensated on the side of the case 5 Tap Zero on the touch screen 6 Configure the millivolt sourcing device to deliver zero ...

Page 35: ...ed if you want to proceed with the calibration A progress indicator will appear 14 When the process completes Span calibration is finished To perform a temperature calibration Cold Junction Trim Needed Thermocouple wire type S and or K temperature sourcing device 1 Open the Analog Input Calibration page 2 Make sure that the selected input at the top of the screen is T C K or T C S depending on whi...

Page 36: ...alue based on which to deliver a corresponding voltage 6 Configure the temperature sourcing device to deliver the proper voltage 7 Wait for the Current Value displayed on the screen to get as close to the target voltage as possible 8 Tap Calibrate Tap Yes when asked if you want to proceed with the calibration A progress indicator will appear 9 When the process completes temperature calibration is ...

Page 37: ...on page the displayed value will be 60 0 NOTE This field will also change the number of decimal places used for the Valve Maximum field in the Valve Setup menu D Gas Selection Drop Down List This drop down list allows you to select the gas used in the selected flow control valve If used valve 1 must be used with N2 and valve 2 must be used with NH3 these are fixed Valve 3 may be used with Dissocia...

Page 38: ... 0scfh 13112 CO2 Scrubber 33095 Fuse 2 amp slow blow 20315 Sample Tubing Assembly 31033 In Line Filter 37048 Bowl Filter Assembly 31027 Element for Bowl Filter 13084 Span Gas Calibration Kit including regulator 30054 Zero Gas Calibration Kit including regulator Full PGA Units 13533 Standard 3 Gas PGA CO CO2 CH4 with O2 13544 4 Gas PGA Standard plus H2 measurement 13548 3 Gas PGA for Corrosive Gase...

Page 39: ...TION OF IMPLIED WARRANTIES SO THIS LIMITATION MAY NOT APPLY TO YOU SSI is not responsible for returning to you product which is not covered by this limited warranty If you are having trouble with a product before seeking limited warranty service first follow the troubleshooting procedures that SSI or your authorized SSI dealer provides SSI will replace the PRODUCT with a functionally equivalent re...

Page 40: ...ated for revised capability of H2 sensor 11 16 2012 2107 C Updated for added nitriding calculations available compatibility with ammonia gas Updated parts list Tools menu updated as needed 2 7 2014 2135 D Added Calculation Factors Added Appendix 1 for common Modbus registers 6 20 2014 2138 E Added suggested calibration schedule Added CO exhaust warning 2 21 2017 2207 ...

Page 41: ..._run_min The total time in minutes that the pump has run since the last time memory was cleared or a manual reset took place This value plus pump_run_wks will provide the total amount of time the pump has been running When this number reaches 10080 pump_run_wks is increased by 1 and pump_run_min is reset to zero 215 pump_run_wks The total time in weeks that the pump has run since the last time mem...

Page 42: ...4 sample_control Sample valve control 225 flow_timer Flow control 226 base_status Status of base 0 OFF 1 pump ON 2 sample delay 3 measure delay 4 delay OFF 5 ON 227 alarm_bits Alarm bit map Bit 0 low flow Bit 1 base communications Bit 2 max factor Bit 3 min factor Bit 6 programmer alarm Big 7 high byte is acknowledge Bit 4 and 5 not used ...

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