Super Systems MGA 6010 User manual

MGA 6010
Multi-Gas IR Analyzer
(CO, CO2, and CH4Gas Analyzer
with Optional H2Measurement and
% Carbon, % Dissociated Ammonia, % NH3, KN, and
KCCalculation 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.

MGA 6010 Operations Manual
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Super Systems Inc.
USA Office
Corporate Headquarters:
7205 Edington Drive
Shipping Address:
7245 Edington Drive
Cincinnati, OH 45249
Phone: [phone]
http://www.supersystems.com
Super Systems Europe
Unit E, Tyburn Trading Estate,
Ashold Farm Road, Birmingham
B24 9QG
UNITED KINGDOM
Phone: [phone]
http://www.supersystemseurope.com
Super Systems México
Sistemas Superiores Integrales S de RL de CV
Acceso IV No. 31 Int. H Parque Industrial
Benito Juarez
C.P. 76120 Queretaro, Qro.
Phone: [phone]
http://www.supersystems.com.mx
Super Systems China
No. 369 XianXia Road
Room 703
Shanghai, CHINA
200336
Phone: [phone]
http://www.supersystems.cn
Super Systems India Pvt. Ltd.
A-26 Mezzanine Floor, FIEE Complex,
Okhla Indl. Area, Phase –2
New Delhi, India 110 020
Phone: [phone]
http://www.supersystemsindia.com

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Table of Contents
Introduction................................................................................................................................................... 5
Specifications ................................................................................................................................................ 6
Unpacking the Device.................................................................................................................................... 7
Mechanical Installation ................................................................................................................................. 7
Enclosure Mounting ........................................................................................................................................7
Wiring Connections ....................................................................................................................................... 8
Plumbing Connections....................................................................................................................................9
Basic Operating Description ....................................................................................................................... 11
Default Screen ............................................................................................................................................ 11
Pump Operation .......................................................................................................................................... 12
Carbon Calculation...................................................................................................................................... 12
Chart ........................................................................................................................................................... 13
Chart Sub Menu.............................................................................................................................................14
Menu Lists................................................................................................................................................... 15
Carbon Calculation........................................................................................................................................16
Nitrider Calculation (Available on Units Configured for Nitriding & FNC Applications)...........................17
Sessions.........................................................................................................................................................18
Pump Control ................................................................................................................................................20
Sensor Calibration ........................................................................................................................................20
Performing a Zero Calibration.................................................................................................................23
Performing a Span Calibration ................................................................................................................24
Automatic Sampling Parameters.................................................................................................................24
COF/PF Adjustment Increment................................................................................................................24
COF/PF Adjustment Interval (minutes) ...................................................................................................25
Minimum COF / PF Value .........................................................................................................................25
Maximum COF / PF Value ........................................................................................................................25
COF / PF Adjustment Mode......................................................................................................................25
Minimum Temperature for sampling (0 = disabled)...............................................................................25
Communications and Source Setup............................................................................................................. 26
IP Address .................................................................................................................................................26
Atmosphere/Temp Sources .....................................................................................................................27
Port Setup ................................................................................................................................................. 28
Instrument Setup ..........................................................................................................................................29
Calculation Factors ..................................................................................................................................29
General Setup ...........................................................................................................................................35
Security Settings.......................................................................................................................................35
Analog Output Setup.................................................................................................................................36
Factory Default Settings...........................................................................................................................36
Other Settings ...........................................................................................................................................36
Language Setup ........................................................................................................................................36
Auto Calibration Setup.................................................................................................................................. 37
Gas Alarm Setup ...........................................................................................................................................38
Instrument Information ................................................................................................................................38
General Information .................................................................................................................................38
Calibration Dates ......................................................................................................................................39
Power Status.............................................................................................................................................39
Tools...............................................................................................................................................................39
Database Maintenance............................................................................................................................. 39
Pressure Sensor Calibration ................................................................................................................... 40
Thermister Calibration ............................................................................................................................. 40
SuperCalc..................................................................................................................................................40
Set User Cal / Load User Cal ...................................................................................................................40
Valve Setup................................................................................................................................................41
Shut Down Interface......................................................................................................................................41
Parts List and Internal Components ........................................................................................................... 42

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Revision History .......................................................................................................................................... 45
Appendix A: Piping Diagram........................................................................................................................ 46
Appendix B: Digital Inputs on the MGA 6010 ............................................................................................... 47
Appendix C: Modbus Registers ................................................................................................................... 48
Appendix D: Configuration Parameters ...................................................................................................... 66

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Introduction
The Model MGA 6010 (see part numbers in the Parts List on page 42) is a Multi-Gas IR analyzer. It
measures Carbon Monoxide (CO), Carbon Dioxide (CO2) and Natural Gas (CH4) typically found in an
endothermic atmosphere. The measurement of these gases, combined with furnace temperature
information, allows the MGA 6010 to calculate the percent Carbon (%C) of the measured gas. A Hydrogen
(H2) sensor can also be incorporated as an option to provide a more complete picture of the measured
gas.
For nitriding and ferritic nitrocarburizing (FNC) applications, the MGA 6010 can calculate carburizing
potential (KC) and nitriding potential (KN).
Finally, the MGA 6010 can be configured for compatibility with environments containing ammonia (NH3)
gas. NH3compatibility must be specifically requested when the MGA 6010 is ordered.
NOTE: Calculation of KCmay have inaccuracies in the presence of ammonia.
IMPORTANT!
Do not use a MGA 6010 for gas analysis with NH3-containing gas if the MGA 6010 has not been
configured with NH3compatibility. Any use of a non-NH3compatible MGA 6010 with NH3-
containing gas will void the product warranty.

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Specifications
The unit is designed and manufactured for the atmosphere heat treating industry; however, its uses go
beyond the scope of these applications.
CO:
Range: 0 –30% of gas concentration.
Accuracy: +/-1% of full scale (+/-0.3% of gas concentration, based on 30%).
Resolution: 0.01%
CO2 Low:
Range: 0 –2% of gas concentration.
Accuracy: +/-1% of full scale (+/-0.02% of gas concentration, based on 2%).
Resolution: 0.001%
CO2 High:
Range: 0 –20% of gas concentration.
Accuracy: +/-1% of full scale (+/-0.2% of gas concentration, based on 20%).
Resolution: 0.01%

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CH4:
Range: 0 –20% of gas concentration.
Accuracy: +/-1% of full scale (+/-0.2% of gas concentration, based on 20%).
Resolution: 0.01%
H2:
Range: 0 –100% of gas concentration.
Accuracy: +/-1% of full scale (+/-1% of gas concentration, based on 100%).
Resolution: 0.1%
* 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 pump (when necessary)
Measurement Method (CO, CO2, CH4): Non-Dispersive Infrared (NDIR)
Measurement Method (H2): Thermal Conductivity
Repeatability: 1% of full scale
Recommended Calibration Interval: Annual
AC Power Requirements: 110VAC (can be modified to 220V upon request)
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 MGA:
(1) MGA 6010 Gas Analyzer
(1) Bowl Filter Assembly (attach to “Sample Inlet” port)
(1) ¼” Male NPT to 3/16” barb fitting (attach to “Aux. Cal. Gas Inlet” if desired)
(1) Operations Manual
(1) XGA Viewer CD
(2 ) ¼” Male NPT to calibration gas inlet hose fitting (attach to “Zero and Span Cal. Gas Inlet” if desired)
If any of these items is missing or damaged please contact Super Systems Inc. at 513-772-0060.
Mechanical Installation
Enclosure Mounting
It is recommended that the MGA 6010 be mounted as close to the sampling point as possible, since that
will reduce the length of the plumbing lines that will need to be maintained. It is intended for use in a
heat treating environment, but care should be taken not to mount it too close to a furnace or other heat
source. The operating temperature of the enclosure should be maintained below 122°F (50°C). If
necessary, a heat shield can be mounted behind the enclosure to reduce the amount of radiant heat that
the MGA is exposed to. In most cases, this will not be necessary.
The enclosure is heavily vented to prevent the buildup of potentially harmful gases in the unlikely event of
an internal leak. This venting will also reduce the internal temperature by allowing the free flow of
ambient air around the internal components.

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Wiring Connections
Terminal blocks inside the instrument are available for the following purposes:
Each terminal block is numbered according to the included electrical drawing. Knockout holes in the
enclosure have been provided to simplify wiring connections. Knockouts are located on the bottom of the
enclosure. Additional or alternate locations can be added as needed. Please note that due to the
potential for electrical interference, it is recommended that communication wires not be run in parallel to
AC power wires.
The right side of the enclosure also contains two Ethernet ports, one USB A port and one USB B port.
These can be used to communicate to the MGA 6010. For detailed information on the use of these ports,
please see the section of this manual, Communications and Source Setup.
Electrical drawings are available from SSi at:
http://www.supersystems.com/documentation/typical-schematicsdrawings/

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Plumbing Connections
There are five plumbing connections on the MGA 6010:
Sample Inlet –The incoming gas to be sampled should be routed through this port after passing through
the included bowl filter.
Sample Vent –After sampling, the gas will exit the enclosure through this port. Due to the potentially
harmful nature of the gas being measured, the gas should be vented to a place in accordance with local
regulations and safety standards.
Zero and Span Calibration Gas Inlets –These are ¼” NPT female ports for connecting to calibration
gases. For more information on acceptable calibration gases see the Sensor Calibration section of this
manual. The incoming pressure of the gas will need to be adjusted to allow the flow to be the same for
the calibration gas and the sample gas flow rate. The incoming pressurized gas goes through a small
fixed orifice inside the analyzer, which should require between 20 and 50 psi to maintain proper flow.
These ports are used with the automatic calibration system to provide calibrations at predetermined
intervals or events. The use of these ports is not required for the operation of the MGA 6010.
Auxiliary Calibration Gas Inlet –This ¼” NPT female port provides another entry point for both zero and
span calibration gases. If calibrations are being performed manually, this port should be used for both
gases.
The flow of gas through the MGA 6010 is controlled by solenoid valves. Each valve is normally closed, and
for safety purposes all valves will shut to prevent unwanted furnace gases from entering the instrument
when power to the enclosure is lost or the specified sampling parameters are not met.
Appendix A: Piping Diagram shows the plumbing connections.

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