Super Systems PGA 3510 User manual

PGA 3510
Portable Multi-Gas IR Analyzer
(CO, CO2, and CH4Gas Analyzer
with O2and 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 [phone] for assistance.

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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
Units 3 & 4, 17 Reddicap Trading Estate,
Sutton Coldfield, West Midlands
B75 7BU
UNITED KINGDOM
Phone: [phone]
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: [phone]
http://www.supersystems.com.mx
Super Systems China
No. 335 XianXia Road
Room 308
Shanghai, CHINA
200336
Phone: [phone]
http://www.supersystems.com
Super Systems India Pvt. Ltd.
A-26 Mezzanine Floor, FIEE Complex,
Okhla Indl. Area, Phase – 2
New Delhi, India 110 020
Phone: [phone]

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Table of Contents
Introduction............................................................................................................................................. 4
Specifications .......................................................................................................................................... 5
Unpacking the Device .............................................................................................................................. 6
Basic Operating Description .................................................................................................................... 7
Default Screen......................................................................................................................................... 7
Pump Operation ...................................................................................................................................... 8
Carbon Calculation .................................................................................................................................. 8
Chart....................................................................................................................................................... 9
Chart Sub Menu.............................................................................................................................................10
Menu Lists............................................................................................................................................. 11
Carbon Calculation........................................................................................................................................13
Nitrider Calculation (Available on Units Configured for Nitriding & FNC Applications)........................... 13
Sessions.........................................................................................................................................................14
Pump Control ................................................................................................................................................16
Sensor Calibration ........................................................................................................................................16
Performing a Zero Calibration................................................................................................................. 17
Use of a CO2Scrubber for Zero Calibrations ..........................................................................................18
Performing a Span Calibration ................................................................................................................18
Calibrating the Oxygen Sensor ................................................................................................................19
Automatic Sampling 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
Instrument Information ................................................................................................................................31
General Information .................................................................................................................................31
Calibration Dates......................................................................................................................................31
Power Status.............................................................................................................................................31
Tools...............................................................................................................................................................32
Database Maintenance.............................................................................................................................32
Pressure Sensor Calibration ...................................................................................................................33
Thermister Calibration.............................................................................................................................33
SuperCalc..................................................................................................................................................33
User Manual.............................................................................................................................................. 33
Set User Cal / Load User Cal ...................................................................................................................33
Calibration Log..........................................................................................................................................33
Analog Input Calibration...........................................................................................................................33
Valve Setup................................................................................................................................................36
Parts List............................................................................................................................................... 38
Warranty ............................................................................................................................................... 39
Revision History..................................................................................................................................... 40
Appendix 1: PGA 3510 Common Modbus Registers................................................................................. 41

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Introduction
The Model PGA 3510 (see part numbers in the Parts List on page 38) is a portable Multi-Gas IR analyzer
with an Oxygen (O2) cell. 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 PGA 3510 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 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. NH3compatibility must be specifically requested when the PGA 3510 is ordered.
IMPORTANT!
Do not use a PGA 3510 for gas analysis with NH3-containing gas if the PGA 3510 has not been configured
with NH3compatibility. Any use of a non-NH3compatible PGA 3510 with NH3-containing gas will void the
product warranty.
WARNING!
The exhaust of the PGA 3510 should be burned or vented outside to avoid exposure to carbon
monoxide. Extended exposure to the exhaust could be hazardous to your health.

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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: 0.00 to 30.00 %
CO2range: 0.000 to 2.000 %
CH4range: 0.00 to 15.00 %
O2range: 0.1 to 25.0%
H2range: 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 pump (when necessary)

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Measurement Method (CO, CO2, CH4): Non-Dispersive Infrared (NDIR)
Measurement Method (O2): Electrochemical
Measurement Method (H2): Thermal Conductivity
Accuracy and repeatability: ±1% of full scale
Recommended Calibration Interval: Annual
Flow Meter: Inside case lid and also on-screen
AC Power Requirements: 90 to 230 VAC, 50 to 60 Hz, 60 Watts
DC 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 PGA:
1. Portable Gas Analyzer
2. Bowl Filter
3. Sample Tubing
4. In-Line Filter
5. Notepad
6. Touch Screen Stylus
7. XGA Viewer Software CD
8. USB Cable
9. CO2Scrubber
10. Power Cord
11. Product Manual

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Basic Operating Description
The Model PGA 3510 has been designed for the simultaneous analysis of CO, CO2and CH4in heat-treat
furnace atmosphere gases. It uses a color touch screen display / operator interface for data entry and for
viewing. Selections can be made on the screen using a finger or a stylus. Avoid the use of sharp objects
(pens, paperclips, screwdrivers, etc.) as they can cause permanent damage to the screen and void the
warranty of the instrument.
After the power switch is turned on, it will take approximately 30 seconds for the PGA 3510 software to
automatically load. Once the software is properly loaded, the instrument is ready to use. When the
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 H2accuracy, 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 default screen will be displayed.
A – Measured values of CO, CO2, and CH4 (and H2, if the H2sensor is present)
B – Pump status indicator / Button to change pump status
C – Button to access menu list
D – Session status indicator
E – Temperature / Instrument Temperature indicator
F – Button for Carbon Calculation screen
G – Automatic Carbon Calculation Adjustment indicator
H – External Instrument Communications status indicator
I – Measured value of Oxygen
J – Button for Trend Chart screen
K – Numeric Flow indicator
L – Visual Flow indicator

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Pressing the Return button at the bottom right of the operator interface on any screen will take the
display to the default. It may be necessary to press the Return button multiple times.
Pump Operation
Initially, the pump will be off. The pump should remain off while sampling an endothermic generator or
any other atmosphere under positive pressure. The pump should also remain off during calibration. For
proper operation, the flow of gas through the sensors should be between 1.0 and 2.0 SCFH. If the flow
meter on the right of the screen or on the inside of the lid does not indicate sufficient flow, turn the pump
on. When accessed from the main screen, 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
CH4along 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 PGA 3510 can be used as a comparison to the
carbon percentage measured by a furnace’s oxygen probe. This is accomplished either by manually
entering the Probe Temperature, Probe Millivolts, and the Probe CO Factor into the PGA 3510 or by
obtaining the information automatically via RS-485 communications to the Furnace Carbon Controller.
Providing the probe information allows the PGA 3510 to suggest an adjustment for the probe CO Factor
(or Process Factor) in order to keep the oxygen probe measuring properly.

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Using infra-red analysis is considered a more accurate method for determining the percent carbon of a
gas compared to using an oxygen probe alone. The single point oxygen probe assumes a theoretical
mixture of endothermic gas to infer the percent carbon whereas the gas analyzer will measure the exact
composition of the process gas. The percent carbon determined by the gas analyzer can then be used to
adjust the carbon percentage determined by the oxygen probe.
Chart
The Chart Display shows between 1 hour and 24 hours of process variable data on the screen and can be
scrolled back to view all of the data stored on the flash card. The vertical timelines change as the time
changes on the screen. The function buttons run 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. Clicking on the OK button on this screen
will close the screen down and return to the Chart Display screen.
The Refresh button - - will refresh the screen’s trend data if the screen is not in real-time mode.
The left-pointing green arrow button - - will move the chart’s view backward in time by the
specified chart interval.
The chart interval button - - will determine the number of hours displayed on the trend chart. The
options are: 1 Hour, 2 Hours, 4 Hours, 8 Hours, 12 Hours, or 24 Hours.
The right-pointing green arrow button - - will move the chart’s view forward in time by the
specified chart interval.

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The right-pointing arrow with the vertical line next to it button - - will toggle between viewing the
chart in or out of real-time. When in real-time mode, the chart will automatically be updated once a
minute.
Chart Sub Menu
There is a sub-menu available by putting a finger or a stylus anywhere on the chart and holding it there
for a couple of seconds. The sub-menu will have the following options available: Zoom, Restore, Add
Note, Data, and Exit.
The Zoom option will allow the user to zoom in on a particular part of the screen. Once this has been
selected, the user can take a stylus or a finger and create a box around the data. Once the user releases
the stylus or finger, a zoom is no longer possible, and the 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 9010
instrumentation. Pressing the Add Note option displays a screen where the operator can enter the
operator ID or initials and a note. The user has the option to enter a note using either the operator
interface keyboard and typing or using the Signature mode and writing the note with the stylus.
The Data option will show the trend data as a data grid instead of the trend lines on a chart. This
functionality is exactly the same as if the user pressed the Datagrid View button - - from the chart
screen.
Exit will close out the sub-menu without selecting an item.

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Pressing the red ‘X’ in the top right-hand corner of the screen will take the user back to the status
screen.
Menu Lists
Accessing the menu screen will show three or four available 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 and Instrument Information screen.

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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.

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To access any items on the menu list, touch the item to highlight it and then press Detail. A specific
description of each item on the list follows.
Carbon Calculation
Please see the Carbon Calculation section starting on page 8.
Nitrider Calculation (Available on Units Configured for Nitriding & FNC Applications)
When configured for nitriding and ferritic nitrocarburizing (FNC) applications, the PGA 3510 has the ability
to provide a calculation of values essential those processes—specifically, nitriding potential (KN) and
carburizing potential (KC). To access these values, open the Nitrider Calculation page. NOTE: If the PGA
3510 unit you are using does not have the Nitrider Calculation option, and you would like this feature
added, please contact SSi at [phone].
The Nitrider Calculation page displays data on current atmosphere parameters such as temperature and
measured values for % CO, % CO2, % CH4, % O2, and % H2(if the H2sensor is installed). The calculated
value for %C is also shown.
User-provided flow values for N2, NH3, DA, and CO2are 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, allowing you to change the
value. For the purpose of KN and KC calculations, any valid gas flow unit (for example, cubic feet per
minute, or cfm) may be used. The flow unit must be the same for all gases. NOTE: If one or more of the
flow gases do not show up in the list, it is likely that the gas flow valve is not enabled in the Tools →
Valve Setup menu. Refer to the Valve Setup section on page 34 for more information.
KN provides a measurement of the amount of nitrogen that can be diffused into a metal (e.g., iron); it is a
derived measurement based on the partial pressures of NH3and H2. The PGA 3510 performs the
calculation of KNusing user-provided flow values and displays the calculated KN value on the Nitrider
Calculation page.

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KCprovides a measurement of the amount of carbon that can be diffused into a metal; it is derived from a
calculation involving the partial pressures of CO2, H2, CO, and H20. The PGA 3510 performs the required
calculation using user-provided flow values and displays the calculated KCvalue on the Nitrider
Calculation page.
Sessions
The instrument is logging data any time that it is powered on. Data of interest can be viewed by entering
its date and time.Users can apply custom tags to sections of data, allowing 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 selections with custom entries, see the “Tools – Database
Maintenance” section of this manual.
Using the pull-down menus, select the Operator Name and Equipment Name from the list of available
selections. Then begin the session by pressing Start. After confirming the beginning of a session, a
sessions summary screen will be displayed. To end the session, press the red End button.

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This screen will identify sessions within the date range specified at the top of the screen. As a default,
sessions from the past 24 hours are shown. By expanding the data range, additional sessions can be
seen. These sessions are 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 manual. To leave the
Chart view, press the red X in the upper right hand corner of the screen.

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Pump Control
The Pump Control screen will identify and allow the modification of the pump status (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.

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Two types of calibrations can be performed on the NDIR sensor; Zero and Span. The Zero calibration
should be performed with a gas that has none of the measured gases in it. Ideally this would be pure
Nitrogen or Argon. The concentration of the Span calibration gas should closely resemble the gas that is
being measured. For a heat treating application measuring endothermic gas, the ideal composition
would be:
•CO: 20%
•CO2: 0.5%
•CH4: 5.0%
•H2: 40%
•N2: Balance
Since the accuracy of the calibration gas directly influences the resulting accuracy of the instrument, the
highest possible accuracy grade should be obtained. Some gas suppliers refer to this as a “Certified
Primary Standard”. The high degree of accuracy is not required to obtain nominal values that exactly
match the values shown above. The 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 regulator with a low pressure secondary stage be used.
It is good practice to begin the flow of gas before attaching the calibration gas to the instrument. This will
prevent any high pressure bursts from entering the instrument.
Calibration gases can be obtained from Super Systems, however they can also be obtained from any
supplier of custom gases.
Hydrogen Cell Note:
It is recommended that the instrument be turned on for three hours prior to performing an H2 calibration.
Performing a Zero Calibration
From the Sensor Calibration screen, be sure that the button at the upper left of the instrument is
selecting Zero Calibration and not Span Calibration.

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When this is selected, the target values will automatically go to zero. Begin the flow of gas at the
appropriate rate, and allow the readings to come to equilibrium. This occurs when the actual values are
not moving in a specific direction, and they display only slight movements up and down. This should take
approximately 45 seconds.
There is a column showing the Status of each gas. In this area the instrument is making a comparison
between the Target value and the Actual value and providing feedback based on the amount of difference
between the two. There are three possible words that can appear in this area:
“OK” – The gas is within 10% of where it is expected to be.
“OK?” – The gas is between 10% and 20% of where it is expected to be. This could indicate an issue with
the calibration gas, so the calibration gas and the associated tubing should be checked and verified to be
free from leaks or improper gas composition. This message does not necessarily indicate that there is a
problem with the sensor or the calibration. It is meant only to have the operator make sure that the
proper procedures are being followed.
“BAD” – The gas is more than 20% from where it is expected to be. The same items should be checked as
described above. This message could indicate an issue with the sensor.
Regardless of the status of each of the gases, the instrument can be calibrated by waiting for the
readings to stabilize and pressing Start Calibration. Timers will begin to count down, and when they
reach zero the Actual values should be the same as the Target values (allowing for slight variations as a
result of gas fluctuations).
Use of a CO2Scrubber for Zero Calibrations
If an appropriate Zero calibration gas is not available, the included CO2Scrubber can be used.
The scrubber is designed to remove CO2from ambient air. Ambient air should not have a significant
amount of CO or CH4. However it does have some CO2in it. Using the scrubber will result in the
instrument measuring a gas with no CO, CO2, or CH4which 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 CO and/or CH4. Also, the scrubber uses an expendable media that loses its
effectiveness after repeated uses. For these reasons, Super Systems Inc. recommends the use of
Nitrogen or Argon instead of the scrubber whenever possible.
To use the CO2scrubber: Remove the protective caps from the scrubber and attach it to the inlet hose on
the PGA 3510. The pump should then be turned on. This will pull ambient air through the scrubber and
into the analyzer.
Always replace the caps on the CO2scrubber after use. If it is left exposed to ambient air, the media will
lose its effectiveness. The amount of time that the Scrubber is exposed to ambient air is directly related
to its effective life span. If the protective caps are replaced after each use, the scrubber will provide
years of service.
Never mistake the scrubber for a particulate filter. Not only is it not designed for this purpose, but
because it removes the CO2from the gas it will result in very inaccurate readings. For these reasons, it
should never be used during a Span calibration.
Performing a Span Calibration
A Span calibration is performed the similarly to the zero calibration but with two small changes. First,
the selector button at the top should be on Span Calibration instead of Zero Calibration.
Second, the gas values for the specific cylinder of gas being used need to be entered into the Target
values. To do this, press the blue box associated with each gas and enter the value shown on the
cylinder. For example, the nominal value for CO may be 20%, but your cylinder may actually have 19.96%
CO. 19.96 is the value that should be entered as a Target.

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After the gas values have been entered, proceed with the calibration in the same manner as with the zero
calibration. Never perform a span calibration without first doing a zero calibration.
Calibrating the Oxygen Sensor
The PGA 3510 uses an electrochemical oxygen sensor that should last approximately two years
(depending on usage). It measures oxygen to a resolution of 0.1%, so it is not suitable for calculating
carbon in a furnace. Its intended use is for troubleshooting problems such as air and/or water leaks. The
information from this sensor is not used in the calculation of percent carbon.
Calibration of the Oxygen sensor does not require a special calibration gas. Ambient air contains 20.9%
O2, and since that concentration is relatively stable, it can be used to perform a span calibration on the
sensor. There is no drift at the low range of the sensor so there is no Zero Calibration function 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 value match the Target value.
Automatic Sampling Parameters
This instrument is capable of communicating directly with a control instrument. This is valuable because
it will provide real-time entry of the temperature and millivolt information from the probe, allowing for an
accurate comparison between the IR % Carbon and the Probe %Carbon. To establish this
communications link, see “Communications and Source Setup – Atmosphere/ Temp Sources.”
The Automatic Sampling Parameters screen will allow the user to adjust the way that the PGA 3510
updates the COF / PF in the atmosphere controller. All of the parameters on this page can be
disregarded if the “COF/PF Adjustment Mode” is set to Monitor mode. These parameters only apply when
the instrument is in Control mode.

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COF/PF Adjustment Increment
When adjustments are made automatically, this value indicates the size of the step that is made when the
COF/PF is changed. It is recommended that this number remain low to avoid making sudden changes to
the process that could be caused by temporary conditions.
COF/PF Adjustment Interval (minutes)
This indicates the frequency that automatic adjustments are made. We recommend making small
changes at 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 Adjustment Mode
This selection determines if changes to the COF/PF will be made automatically or if the instrument will
monitor the conditions without making any changes. When in Monitor mode, a COF/PF will continue to be
suggested, but no modifications will be made to the atmosphere controller.