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.

PGA 3510 Operations Manual
Super Systems Inc. Page 2 of 42
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.