madur electronics GA-21 plus User manual

FLUE GAS ANALYSER
GA-21 plus
Operating manual
Version: 2.0
04/2013

www.madur.com Manual GA-21Plus
Index
1. Introdu tion....................................................................................................................4
1.1. Use of this operating manual................................................................................4
2. Maintenan e...................................................................................................................5
2.1. Gas sensors............................................................................................................5
2.2. Gas system.............................................................................................................5
2.3. Battery.....................................................................................................................5
2.4. Servi e intervals.....................................................................................................6
2.5. Errors during operation.........................................................................................6
2.6. Swit hing off after use...........................................................................................6
3. General information......................................................................................................7
4. Constru tion..................................................................................................................9
4.1. Elements of gas ir uit..........................................................................................9
4.1.1. Gas probe with in-line filter...........................................................................9
4.1.2. Gas pump......................................................................................................10
4.1.3. Gas hamber.................................................................................................10
4.2. Measurement system...........................................................................................10
4.2.1. Gas sensors..................................................................................................10
4.2.2. Ambient temperature sensor.......................................................................12
4.2.3. Fleue gas temperature sensor....................................................................12
4.2.4. Gas hamber temperature sensor..............................................................12
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. Interfa e RS232C..........................................................................................16
4.3.5. Power supply.................................................................................................17
5. Operation......................................................................................................................18
5.1. Use of the keyboard.............................................................................................18
5.1.1. Des ription of the keys................................................................................18
5.1.2. Sele ting menu options...............................................................................19
5.1.3. Entering numbers.........................................................................................20
5.1.4. Editing text....................................................................................................20
5.2. Basi operating instru tions..............................................................................21
5.2.1. Setting-up the analyser................................................................................21
5.2.2. Swit hing on..................................................................................................21
5.2.3. Swit hing off / Standby................................................................................21
5.2.4. Initial alibration...........................................................................................23
5.2.5. Measurement Parameters............................................................................24
5.2.5.1. Fuel sele tion..........................................................................................25
5.2.5.2. Averaging time........................................................................................27
5.2.5.3. Referen e Oxygen parameters (O2R)...................................................27
5.2.5.4. Boiler parameters....................................................................................28
5.3. Displaying the measurement results.................................................................29
5.3.1. Current Values..............................................................................................29
5.3.2. Averaged values...........................................................................................30
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5.3.3. The averaging pro ess.................................................................................31
5.4. Pressure/Draft measurements............................................................................32
5.5. Soot (smoke) Measurement................................................................................33
5.6. Options..................................................................................................................34
5.6.1. Devi e info.....................................................................................................35
5.6.2. Sensors..........................................................................................................36
5.6.2.1. Sensor CO (only in dual CO sensor onfiguration)............................36
5.6.2.2. CO range..................................................................................................37
5.6.2.3. O2 ell alibration...................................................................................37
5.6.2.4. External hannels...................................................................................38
5.6.2.5. Sensor alibration...................................................................................40
5.6.3. Settings..........................................................................................................43
5.6.3.1. Ba klighting.............................................................................................43
5.6.3.2. Contrast....................................................................................................43
5.6.3.3. Clo k.........................................................................................................44
5.6.3.4. Printer.......................................................................................................45
5.6.3.5. Language/Country..................................................................................46
5.6.3.6. A ousti 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 Servi e...............................................................................................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 (Noti e) 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
5.8. Data-logger...........................................................................................................56
5.9. Printer....................................................................................................................56
5.9.1. Printing the ontents of a s reen................................................................56
5.9.2. Printing of all results....................................................................................56
6. Gas blo k diagram......................................................................................................58
7. Menu stru ture.............................................................................................................59
7.1. Stru ture of the main menu................................................................................59
7.2. Stru ture of the menu STORE............................................................................60
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www.madur.com Manual GA-21Plus
1. INTRODUCTION
Congratulations on your purchase o the microprocessor-controlled lue 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 o using the extra capabilities o
this analyser, o examining measurement results, checking service intervals and many
others. Please read the operating manual care ully. It contains valuable tips and in orma-
tion or problem- ree operation. Regular maintenance will help to keep your analyser
ready or 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 o the sections o this manual.
2. Maintenan e
This section contains important in ormation designed to keep your analyser work-
ing and to save you time and trouble.
3. General information
This describes the most important characteristics o your new analyser.
4. Constru tion
A knowledge o the hardware o the analyser will help you to use the instrument
correctly and to avoid unnecessary down-time.
5. Operation
This section explains the use o the analyser with detailed descriptions o the vari-
ous unctions. It is important to read the sections 5.1 and 5.2 irst. The other sections can
be read when required.
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2. MAINTENANCE
2.1. Gas sensors
The ollowing points are important or maximising the operational li e o the cells
and achieving measurements without errors:
do not exceed the rated concentration;
all the gas cells may react unpredictably to the presence o substances which are
not usually ound in lue gases. For this reason, the analyser may not be cleaned
with chemical solvents. I organic solvents enter the gas chamber, the cells may
become unstable or even su er permanent damage;
some cells require the presence o a bias voltage when not in use. Do not allow
the battery to become ully discharged;
do not switch the analyser o be ore the system is purged o remaining lue gas;
store the analyser in a cool place to reduce the ageing o the cells.
2.2. Gas system
The gas system o the analyser is protected by a double in-line ilter. 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 analyser is maintenance- ree. An acoustic
warning signal is given when the voltage drops below 11 V. The GA-21 plus will switch
o automatically i the voltage should drop below 10.5 V. The analyser will operate or
about 5 hours rom the battery.
Warning:
Some parts of the analyser draw urrent even when the devi e is
swit hed off. If the analyser is not being used then the battery
should be harged fully at least on e a month.
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2.4. Service intervals
The parameters o the electrochemical cells change with time, and there ore it is
necessary to carry out a service periodically. This service should include re-calibration o
the gas sensors using test gases. The recommended service interval is 800 operating
hours or 6 months, whichever comes irst. The analyser is itted with an operating hour
counter and automatically shows when a service is necessary.
The operating time and the number o hours until the next service are shown in
MENU->OPTIONS->madur SERVICE -> DEVICE INFO .
2. . Errors during operation
The analyser checks all circuitry continuously. Should an error become evident,
then this is signalled acoustically and by the message "ERROR" on the screen. The error
can be ound shown on the screen MENU->OP TIONS ->madur S ERVICE -> CONTROL
LIS T .
2.6. Switching off after use
The operating li e o the electrochemical cells is dependent on the usage o the
instrument. The wear and tear on the cells is greater when the cell is exposed to the gas
or 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 swit hed off until all the
gas tubing has been ompletely leared of flue gases and the gas
ells have been purged with fresh air for several minutes.
The GA-21 plus will not normally allow the instrument to be switched o i there
are still traces o lue gas in the system. The analyser will continue to operate until the
signals rom the gas cells are nearly zero. This activity is shown by the message "VENT-
ILATION REMOVE PROBE FROM FLUE".
The [OFF] key must be pressed twice to switch the instrument o completely.
Pressing the key once will put the analyser in the standby mode and the instrument will
remain in this mode until it is activated again by pressing "C" or switched o completely.
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Warning:
Certain onditions, su h as strong ele tro-magneti fields an
ause the analyser to be ome "hung-up". The only solution to this
problem is to swit h the instrument off. It is, however, possible
that the analyser will no longer rea t to the keyboard and an not
be swit hed off.
Info:
Pressing the [OFF] key for a period of about three se onds will always
swit h the analyser off.
3. GENERAL INFORMATION
The GA-21 plus is a multi- unctional lue gas analyser. Electrochemical sensors
are used or the measurement o gas concentration. The instrument can be itted with
between 2 and 4 o these sensors. All analysers are itted with O2 and CO sensors, ur-
ther gas cells must be chosen when the instrument is ordered.
The ollowing 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 irst three gases (O2, CO, NO) are measured directly using the electrochem-
ical cells. The remaining components are calculated. The concentrations o oxygen and
carbon dioxide are shown in percent. The concentrations o the remaining gases are
shown as ollows:
volume concentration in [ppm]
absolute mass concentration in [mg/m3]
mass concentration relative to the oxygen content in [mg/m3]
In addition, the air inlet or ambient temperature and lue gas temperature are
measured. Using the measured temperatures, gas concentrations and the known uel
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parameters the analyser calculates a variety o combustion parameters such as Stack
Loss - SL, E iciency - η, Excess Air - λ, Loss through Incomplete Combustion - IL.
The GA-21 plus also measures di erential pressure.. This can be used to meas-
ure the draught or pressure in the lue gas channel. The instrument is also equipped or
the soot test according to Bacharach methood.
The analyser is also itted as a 3 channel data logger, capable o measuring
voltage or current together with temperature using thermocouples or thermoresistors.
The instrument can be used at a broad range o ambient temperatures (0 - 50°C).
It is itted with a rechargeable battery making it independent o the mains power supply.
Hence, the GA-21 plus is ideally suited or all those involved in the construction,
maintenance and adjusting o heating systems.
The keyboard o the instrument can be wiped clean i 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 measurements on the spot. The EEP-
ROM memory used in the GA-21 plus allows large quantities o data to be stored without
ear o data loss should the instrument be switched o or should the battery be accident-
ally run down. The GA-21 plus comes complete with programmed data or the 18 most
common uels. A urther 10 uels can be programmed by the operator to cover all eventu-
alities.
The RS232C inter ace itted to the GA-21 plus allows all stored data to be read
or later treatment or the instrument can be used on-line with the computer.
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4. CONSTRUCTION
4.1. Elements of gas circuit
4.1.1. Gas probe with in-line filter
The gas probe is used to extract the gas under investigation and to measure its
temperature. The gas probe consists o two parts, the probe pipe with thermocouple (1)
and the probe holder (2).
Pi ture 1. Gas probe with hose and in-line filter
The probe pipe is typically supplies in one o our 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 itted with an anchor cone to simpli y ixation in the lue 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 rom the dust and moisture
present in the lue gases by a ilter (4). The ilter elements (3) should be changed when
dirty to ensure a ree low o gas. The condensate should be removed rom the condens-
ate traps when necessary.
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The plug (6) and hose quick coupler (7) are connected to the ront plate o the
analyser.
4.1.2. Gas pump
The internal gas pump draws the gas into the GA-21 plus and passes it through
the gas chambers. The sel -cleaning pump is a high quality item and is known to be ex-
tremely reliable.
The gas cells operate best with a low rate o 90 l/h, which is set at the actory
and is compensated automatically or low restrictions or changes in battery voltage.
4.1.3. Gas chamber
The gas chamber can be itted with minimum two and maximum six gas sensors.
Oxygen and carbon monoxide cells are standard equipment. The other sensors are
chosen when the instrument is ordered. The gas chamber o the GA-21 plus system is
characterised by minimal dead capacity, which leads to low inertia o the analyser indica-
tions. In addition to the gas sensors, there is a temperature sensor placed in the chamber
or temperature compensation o the sensors.
4.2. Measurement system
4.2.1. Gas sensors
The oxygen concentration is measured using an electrochemical cell. The sensor
signal is directly proportional to the oxygen volume concentration. The oxygen sensor
needs no calibration with standard gases - it is ully calibrated during the initial calibration
when a point corresponding with the contents o oxygen in clean air (20.95%) is determ-
ined.
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The toxic gases are also measured using electrochemical cells.
Table 1 presents all standard gas sensors available in GA-21 plus system.
Gas Cell type Range
O2 5FO 0-20.95 %
O2 MOX-1 0-100 %
CO 5F 0-20000 ppm
CO 5MF 0-10 %
CO A5F 2000 ppm
NO 5NF 0-5000 ppm
NO2 5ND 0-1000 ppm
SO2 5SF/F 0-5000 ppm
H2S 3HL/M 0-1000 ppm
H2 3HYT 0-2000 ppm
CL2 3CLH 0-250 ppm
HCl 3HL(s) 0-100 ppm
Table 1 Available gas cells and ranges
To guarantee long-lasting, trouble- ree unction o electrochemical sensors the
ollowing points are important:
the stated maximum measuring range o the sensor should not be ex-
ceeded.
all the gas sensors can react unpredictably to certain chemicals
which are not typical or combustion gas composition. For this
reason, it is absolutely orbidden to wash the parts o the gas line with
chemical solvents. The vapours rom such solvents can get inside the
gas chamber and result in destabilisation or even permanent damage
o the gas sensors.
the gas sensors are working even when the analyser is switched o -
so the battery should never be disconnected or completely dis-
charged.
the analyser should not be switched o be ore all the lue gases have
been removed rom the analyser's gas circuit.
the sensor chamber must be kept dry.
the switched o analyser should be kept in a cool place, which in-
creases the li etime o the gas sensors.
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4.2.2. Ambient temperature sensor
The ambient temperature is measured by the analyser or use in some o the cal-
culations carried out, such as Stack Loss. This can be carried out either by the temperat-
ure compensation sensor built into the plug o the probe holder (INT) or the external con-
nector T3 (EXT). The temperature sensor is chosen under the suboption:
OPTIONS → SENSORS → ANALOGUE INPUTS.
4.2.3. Fleue gas temperature sensor
The lue gas temperature sensor is situated in the gas probe pipe and plugged
into the PROBE socket on the ront panel o the analyser. This sensor is a NiCr-Ni ther-
mocouple in the standard probe version. The range o such a thermocouple is 50-800oC
in the standard version (1100°C available optionally). A special gas probe with PtRh-Pt
thermocouple can also be used, with a range up to 1600oC. Proper lue gas temperature
measurement is the most important actor or correct calculation o the chimney loss and
other heat engineering results.
4.2.4. Gas chamber temperature sensor
To compensate or temperature dri t o the gas cells, the temperature o the gas
chamber is constantly monitored.
4.2. . Differentia pressure sensor
The GA-21 plus is itted with a precise semiconductor di erential pressure
sensor. Stubs marked +/- PRESSURE situated on the le t side o the ront panel are used
to measure pressure. Negative pressure in lue gas channel (chimney draught) can be
measured with the one stub only; di erential pressure measurement is possible using
both stubs. The measuring range o the pressure sensor is +/- 25 hPa.
4.2.6. Analogue inputs
The three analogue inputs installed can be used to measure voltage or current on
two channels (U and I), temperature using a thermocouple (T1 EXT) and temperature us-
ing a thermistor (T3 EXT). The values measured can be viewed on the screen or stored in
the EEPROM memory.
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Current and voltage inputs – top 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 (-)
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Parameter Thermo ouple Thermistor
Range Ni-CrNi: 1 – 1300°C
Pt-RhPt: 0 – 1600°C
Fe-CuNi: 0 – 700°C
Pt100: 0 – 200°C
Pt500: 0 – 500°C
Resolution 1°C 1°C
4.3. Data input/output system
4.3.1. Keyboard
A ilm keyboard is used in the GA-21 plus analyser which is durable, washable
and highly resistant to external agents. The keys are modern membrane keys with per-
ceptible stroke.
Each press o a key is accompanied by an acoustic signal. The keyboard is
shown in picture B (page 14) and consists o the ollowing elements:
PROBE - Socket or the electrical connection o the probe holder
GAS -Connector or the gas hose
PRESSURE +,- -Connectors or the di erential pressure sensor
RS 232 C -Socket or the RS232C cable
TEMP. 1 -Socket or the temperature channels 1 & 2
U/I 1 -Socket or the current/voltage channels
Function keys -
Arrow keys -
Printer keys -
ON/OFF keys -
Numerals - to
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Pi ture 2. Front elevation pi ture
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4.3.2. Display
The GA-21 plus has a LCD display with graphic capabilities. To improve the
read-out quality, contrast regulation or the display and backlighting are used. Measure-
ment results, calculation results, diagrams, text in ormation, menu options and others ap-
pears on the display.
4.3.3. Printer
The GA-21 plus is itted with an EPSON dot matrix printer capable o printing the
data as graphic or in the orm o 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 itted with a serial RS232C inter ace. The socket is mounted
on the ront o the instrument and marked RS232C. The inter ace allows the GA-21 plus
to communicate with a PC and the so tware madCom is available or carrying out extens-
ive analysis o the stored results.
Top view
1 – +15V out
2 – RxD
3 – GND
4 – TxD
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4.3. . Power supply
The GA-21 plus can be used with mains power supply or be operated rom the
internal battery. A soot test can only be carried out when the mains supply is connected,
otherwise the heating o the probe holder will not unction. The mains cable is attached to
the socket on the le t o the keyboard. Switching the mains supply on or o when the in -
strument is in operation is not recommended. The analyser switches automatically to the
internal battery when the mains supply is disconnected. The LED on the ront panel
shows which power supply is in use.
Red -analyser is switched on and supplied rom the battery. Mains supply
not present.
Green -analyser switched o and mains supply present. The battery is char
ging.
Orange -analyser switched on and mains supply present. The battery is char
ging.
The maintenance- ree 12 V battery has a capacity o 2 Ah. A ully charged battery
will power the instrument or about ive hours.
When the battery voltage drops below 11 V, three acoustic warnings and blinking
o the LED on the ront panel will appear. The message ERROR appears at the top o the
screen and the CONTROL LIST contains the line BATT LOW.
The instrument switches o automatically i the battery voltage drops below 10.5
V.
The battery is charged by connecting the instrument to the mains power supply.
The state o charge can be seen during the initial calibration or read rom the
screen DEVICE INFO:
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5. OPERATION
.1. Use of the keyboard
.1.1. Description of the keys
- Switches to the STORE menu
- Switches to the irst results screen. From the current
results, the use o this key switches between MEAS-
URE and HOLD.
- Switches to the MAIN MENU
- Con irms entries and switches options
to - Alphanumeric keyboard or entering data and or ast
movement between MENU options
- Decimal point when entering data. I used when the
screen is showing RESULTS, this key switches the
zoom unction on or o .
- starts a print-out
- moves the paper orward one line
- switches the analyser on
- switches the analyser to stand-by or o
- moves one step backwards in the menu
- moves one step orward in the menu or, during edit-
ing, moves the cursor one space to the right
and - move the cursor vertically in the menu
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.1.2. Selecting menu options
The menu structure is shown at the end o the manual. The various displayed
menus are leading the user through the structure.
The ollowing picture shows an screen, which explains the di erent types o exist-
ing lines.
Here is an explanation o the movement between the various menu options:
and - move the cursor vertically in the menu
- i the cursor is on the le t side o the Title line, the
key moves one step backwards in the menu
- i the cursor is on the right side o the Option line or
the Title line, the key leads to the displayed Option.
- executes the displayed unction (starts data storage
or example ), in the Command line starts or ends the
respective edit unction (setting the average time or
example ) in the Data line switches (i.e. YES/NO) in
the Switch line
to - or ast movement between MENU options
I a displayed line carries a unction, then there will be a number (1 to 9) on the
le t side o the line. Press the number o the option you want to select, and the cursor will
"jump" to the selected line. I number 4 is pressed in the above demo screen the beam
would move to BOILER DATA.
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.1.3. Entering numbers
Numbers are edited as ollows:
to - digital keys enter corresponding numbers
and - move the cursor within the line
- erases whole number (zero on each position)
- con irms and ends the entry
.1.4. Editing text
Text is edited as ollows:
- switches the keyboard into either digital or alpha
betical mode. When in digital mode the cursor has a
block orm on the screen, in the alphabetical mode
it has the shape o 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 irst press enters the
irst 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 digital and the space
character in alphabetical mode. The space moves
all the next characters one position to the right.
-(DEL) erases the character above cursor position.
This moves all the ollowing characters one position
to the le t.
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