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FGA 300H(X) Horizontal Flue Gas Analyzer User`s Manual

1. NM m ps TBT 6 HHE ER ER al Figure 27 Display Console Circuit Board Note For units fitted with the previous version of the 300D printed circuit board see Appendix F Previous Configurations for the layout of this circuit board Model FGA 300H X Horizontal Gas Analyzer User s Manual 51 Chapter 4 Calibration 4 4 2 Zero Check To perform a zero check complete the following steps Note See Figure 25 on page 46 for the location of the calibration gas port and refer to Regulating the Calibration Gas Flow Rate on page 45 for the correc
2. Djs 626 041 6v9 CO Sey Main Analyzer Accessory Box Figure 64 Local FTC Board Previous Version Model FGA 300H X Horizontal Gas Analyzer User s Manual 147 Appendix F Previous Configurations F 2 Testing the FTC Board and Transformer If the standard testing procedures in Chapter 5 Troubleshooting reaches the point where the FTC circuit board must be checked refer to Figure 64 on page 147 for local wiring or Figure 65 on page 149 for a remote setup and complete the following steps IMPORTANT This symbol indicates Caution risk of electric shock 148 AN Open the hinged cover on the standard Accessory Box or on a standard weatherproof FTC box For an explosion proof flameproof FTC box loosen the locking set screw on top of the FTC box and using a long screwdriver across the slots provided unscrew the cover from the enclosure Using a digital multimeter measure the voltage across pins 5 and 6 on terminal block TB1 in the FTC Accessory Box NOT on the FTC board If the reading is approx
3. Figure 30 Thermocouple Voltage vs Temperature Model FGA 300H X Horizontal Gas Analyzer User s Manual 59 Chapter 5 Troubleshooting 5 2 16 Check the Temperature Sensor cont Table 15 Thermocouple Voltage vs Temperature 0 7981 30 0002 19 8462 30 4153 20 2725 30 8296 20 6990 31 2429 21 1254 31 6553 21 5519 32 0668 21 9783 32 4773 22 4046 32 8868 22 8307 32 9686 23 2565 33 2953 23 6821 33 7029 24 1073 34 1094 24 5322 34 5150 24 9566 34 9196 25 3805 35 3231 25 8039 35 7257 26 2267 36 1272 26 6489 36 5278 27 0705 36 9273 27 4914 37 3259 27 9115 37 7234 28 3309 38 1199 28 7494 38 5154 29 1672 38 9099 29 5841 39 3033 60 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 1c Check the Oxygen Sensor If the sensor furnace operating temperature was within the normal range the troubleshooting sequence should resume here 1 Disconnect the Main Analyzer Unit leads from pins 1 and 2 oxygen sensor connections of terminal block TB1 in the Remote FTC Box 2 Using a digital multimeter measure the resistance between the two oxygen sensor clips Place the positive lead of the multimeter on the inner clip the clip inside the base of the oxygen sensor
4. Standard Weatherproof Remote FTC Box Explosion Proof Flameproof a Remote FTC Box FIC Board F CD p Seen 828 o8 Figure 26 FTC Board R4 and TB1 Locations Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 4 Calibration 4 3 2 Calibration Check cont If necessary adjust the sensor furnace operating temperature using potentiometer R4 on the FTC printed circuit board in the following manner see Figure 26 on page 48 for the location of R4 Note For units fitted with previous versions of the FTC circuit board the location and designation of the temperature adjustment potentiometer is different Refer to Appendix F Previous Configurations for the correct information Turn R4 clockwise to increase the sensor furnace temperature and reduce the percent oxygen reading or Turn R4 counterclockwise to reduce the sensor furnace temperature and increase the percent oxygen reading Each 360 turn of potentiometer R4 will change the reading by about 0 15 oxygen assuming an oxygen level of about 5 which equates to about 3 of the full scale setting Due to thermal inertia of the sensor furnace the change in output will not immediately follow the ch
5. Figure 52 Main Analyzer Unit 1 of 2 Explosion Proof Flameproof 128 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions BTT 0 1801220 0 2 T Try Lac ZST qj eat 64 S Z 1UBlam sayaul sJe1euui uu ui BJD suoisueuJiq 2 1t ZNO ERIC VY L a P OTT JI ol B E S 9 2T2 98 8 See TEE ld 7 10 89 CS Le i 00 Sal1aS 3OwNun4 YaLVaH Jaz jeuy seg anja Lo ts C97 Y 86 S ZST Ge Standard Weatherproof Figure 53 Remote FTC Box 129 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions SS SSS Dimensions are in millimeters inches 3 4 NPT 6 PL m 63 2 48 280 11 02 EN a Y e ei e e a a 42 1 65 63 2 48 199 7 83 Figure 54 Main Analyzer Unit 1 of 2 Explosion Proof Flameproof 130 Model F
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7. Explosion Proof Flameproof Model 300HX Figure 1 The Main Analyzer Unit The Sample System Compartment houses the sample system which consists of the components shown in Figure 2 on page 3 The functions of the sample system components are as follows a heater block with removable thermostat and cartridge heaters to prevent acid components of the flue gas from condensing in the sample system and causing corrosion a zirconium oxide zirconia oxygen sensor a platinum catalyst combustibles detector to monitor incomplete combustion of the fuel by burning it in the presence of excess oxygen Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 1 General Information 11 Overview cont e atemperature controlled sensor furnace to maintain the oxygen sensor at a stable operating temperature and to act as the engine for convective sampling e a convection loop to circulate the sample gases through the sample system Convection Loop Combustibles Detector Cartridge Heater S Thermostat Oxygen Sensor Heater Block Figure 2 The Sample System The Accessory Box which is attached to the Sample System Compartment contains the terminal bloc
8. Bottom Wrench New RU Sensor Wrenc Furnace side view Figure 43 Installing a New Furnace Model FGA 300H X Horizontal Gas Analyzer User s Manual 93 Chapter 6 Parts Replacement 6 2 76 Installing the New Sensor Furnace cont 5 6 Replace the convection loop by fitting it onto the piping Place a wrench on the flat surface of the piping at the top of the furnace Using a torque wrench set the torque to 70 N m 600 in Ib and tighten the convection loop nut while holding the lower wrench steady To tighten the other nut on the convection loop repeat step 6 using a torque setting of 63 N m 540 in Ib Reconnect the two previously removed wires to pins 12 and 14 on TB4 in the Accessory Box Using a digital multimeter check the resistance of the sensor furnace heating element Specific instructions may be found in Chapter 5 Troubleshooting 6 2 7 Replacing the Sensor Furnace cont Assuming that the correct resistance reading was obtained in Step 9 above replacement of the sensor furnace has been successfully completed Conclude the procedure as follows 1 94 Replace the Accessory Box front panel by completing the steps in the Moving the Front Panel Assembly section on page 89 in reverse order Install the Sample System Compartment cover by completing the
9. Explosion Proof Flameproof Enclosure Figure 25 Calibration Port Location 46 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 4 Calibration 4 3 2 Calibration Check A calibration check is started by introducing the calibration gas to the oxygen sensor GE recommends using a calibration gas consisting of 5 O and 95 N as described on page 43 Note Explosion proof flameproof analyzers require a constant 10 50 cc min air flow into the reference air purge connection The idea is to maintain a flow rate that is high enough to be verifiable but not so high as to create a backpressure greater than 1 psi To calibrate the oxygen sensor complete the following steps 1 Introduce a calibration gas mixture containing a known amount of oxygen at the tagged flow rate to the Main Analyzer Unit Refer to Figure 25 on page 46 for the location of the calibration gas inlet port 2 Read the voltage in one of three places press the mV key on the Display Console keypad if one is included in the system or using a voltmeter e measure across pins 1 and 2 on terminal block TB 1 in the Remote FTC Box or measure across pins 1 and 2 on terminal block TB1 in the Accessory Box See Figure 26 on page 48 for the location of the terminal blocks When using the recommended calibration gas 5 O 95 N3 the oxygen sensor output voltage should be 29 99 0 2 mV at 700 C
10. Standard Weatherproof Remote FTC Box Explosion Proof Flameproof Remote FTC Box Figure 20 Accessory Box and Remote FTC Terminal Block Locations Protective Conductor Terminal Model FGA 300H X Horizontal Gas Analyzer User s Manual 29 Chapter 2 Installation 2 5 6 Wiring a 300H X with Remote FTC cont 2 5 66 Connecting the Display Make wiring connections from terminal block TB1 in the 300D Display Console to terminal block TB1 in the Remote FTC Box Refer to Figure 21 on page 31 and Table 4 for the terminal block locations and the proper pin connections Table 4 Display to FTC Box Connections Display Pin Remote FTC Pin Connect TB1 TB1 Oxygen Sensor Oxygen Sensor Combustibles Detector Reference Combustibles Detector Common Combustibles Detector Active Display Screen Note For units fitted with the previous version of the 300D printed circuit board See Appendix F Previous Configurations for the layout of this circuit board 2 5 6C Connecting the Power Power must be connected to both the Display Console TB4 and the Remote FTC Box TB3 Refer to Figure 21 on page 31 and Table 5 for the ter
11. Mounting Flange Figure 11 Explosion Proof Flameproof Model Model FGA 300H X Horizontal Gas Analyzer User s Manual 13 Chapter 2 Installation 2 2 5 NPT Probe Included as part of the analyzer are the 1 4 NPT probe and the 3 4 NPT probe sleeve The probe and probe sleeve carry the sample gas into and out of the analyzer see Figure 12 300H X units intended for operation at temperatures below 950 C 1 750 F include a 32mm 1 1 4 in shroud attached to the end of the probe sleeve WARNING Never attempt to attach a shroud to any unit with a non metallic probe assembly Note A short section of pipe for the furnace or boiler wall two flanges one for the mounting site and one for the analyzer studs nuts plus a suitable gasket are required for mounting WARNING Gas flow must be perpendicular to the probe sleeve or at worst angled downward and away from the open end of the probe sleeve Never angle the gas flow into the open end of the probe sleeve see Figure 12 Mounting Flange Shroud Probe Probe Sleeve Figure 12 Permitted Gas Flow Angles 14 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 2 6 Installation Pipe The standard weatherproof 300H is equipped with a short section of 1 1 2 NPTM threaded pipe proj
12. Figure 49 Combustibles Adjustment Components 122 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix A Rotary Switch Settings A 5 2b An Offset Scale To set the zero and full scale values for an offset scale complete the following steps see Figure 49 on page 122 1 Connect two identical resistors of between 1800 and 2000 ohms across terminal block TB1 pins 5 6 and pins 6 7 2 Install a jumper on pins 2 and 3 of W103 3 4 Adjust potentiometer R111 for a zero value as read on the front panel display Attach the positive lead of a multimeter to pin 3 of terminal block TB2 and attach the negative lead of the multimeter to pin 4 of terminal block TB2 Then adjust potentiometer R112 until a reading of 4 mA or 2 V is obtained Adjust potentiometer R111 for the desired full scale value as read on the front panel display Adjust potentiometer R129 until the analog output corresponds to the value on the front panel display Remove the resistors from TB1 and the jumper from W103 Model FGA 300H X Horizontal Gas Analyzer User s Manual 123 no content intended for this page 124 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions Appendix B Outline and Mounting Dimensions Model FGA 300H X Horizontal Gas Analyzer User s Manual 125 Dou suondo o1 fqns q ss Du s2 44519m seuour s1e1euui Iuu ur B
13. 1811 00g LNOLND 13NVd Id 920 S90 A m 496 820 9 6 872 AMIA LNOYS Id 7 920 99 Jez jeuy sec an QUO eses zo ZH 09 m 6201 92 7 Panel Mount isplay igure 57 300D D F 135 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions say3u sje1euui piuu ur e4D SUOISUBWUIG ql 6 T 64 9 au6ieM ouJaju De UONDUILVIJSL plelus SW Ip 2 29 772 29 S S91 27 m SINO Y9OUY 670 029 40 860 iE CU Lg Ont Zee y 2 00 sanas Joz jeu ZS DA e 5 o o 4 dy STELO eg m T SOT 662 02 TEOT 292 801 922 Standard Weatherproof Figure 58 300D Display Model FGA 300H X Horizontal Gas Analyzer User s Manual 134 Appendix B Outline and Mounting Dimensions ld Z 70 ST X O2W 09 92 09 103 ous Z S ee 9 2 09 t i 9 2 09 bo JA O gt Lee J 870 SZ Z
14. 157 001 f dwg 1703 it Board Previous re ircu isplay Ci D 67 Figure Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix F Previous Configurations NOILVY3dO A022 SMOHS DILVWAHDS X 7038 AOZT NU LN e 038 AOZT al dW3L ASVAYONI OL MO 1SAFAV dell 626 0ZT 913 Q8 V5 J3TIOSLNOO dW3l JOVNYNS 6 ppauuo 8 D 282 T 913 YIWYOJSNVYL M ZM 6 8 VE SS 913 YSWYOISNVYL SANI 89d ONISIM 3INYOISNVIL NO 193135 39VL10A S431V3H IVISONS3HL O o rv tO s nO C ei YOSNAS N39AXO YOSNAS JYNLVYAdWAL YOSNAS DOM OIL DIM WN e D O r tO tO XE PO IN 4 e a e a UL LINA AVIdSIG 1VLISIQ 30123 NOD LAdNI HD MOYLNO9 dW3L S318l1Sf18 WOOD SNIMIA XO JOVNYNS ONISIM XOS AHOSS32OV 517 Rev E Previous ref dwg 1442 Diagram ing Ir W 68 Figure
15. FTC Board Explosion Proof Flameproof Remote FTC Box Figure 21 Standard Display Console and Remote FTC Terminal Block Locations Model FGA 300H X Horizontal Gas Analyzer User s Manual Protective Conductor Terminal 31 Chapter 2 Installation 3J1OSNOO SOINO312313 AVI1d SIG 1300 day 133208 13Nvd 931 OL 0381M AYOLDV3 SISSVHD t tal N 78L LAdLNO N39AXO IN 2 T 281 WYVIV N39AXO LNdLNO Hd Wav 1V uvad LV STVNIWS3L d83 Q00 S341N39 WWO9X09 S3IH IN3 LAN 7 XZ S9dI 8 91 911 P X33 NMOHS LON AlddNS SNIVIA xog 913 SLOWS 9 1 N 9 T SOl8L3INVNVA 39 A8 O3NAANS LON LNSWIYINOIY AYVIA 39 On T OTOT 931 T OTOT9 N3 HLIM SONVNdWOD YOI GIYINOSY HOLIMS LOINNOOSIG SNIVW XHOO LON AINO HOOS 31ON Alddfs SNIVW 9 LINA Y3ZA1YNY NIVIA 103 TT SAN 3931V3H ca eT IVIlLAIN YT SAN SOVNYNS JOSN3S N39AXO JOSN3S J4NIVIIAWIL OT 39N343338 401393130 NOWWOD 6 5 S318l1S18A02 SLAdNI GOIN WW29 S3lH LN3 WUWOZH xt 99dl djM Q00 dX3 000 ASLN3 UU 20 xT S9dl ddM 213 m t mes 00 Saas 3ALLOV T 910 YDS S341N39 WWOS S3l81N3 WWOZD Xe HOOS
16. FTC Board SBR y BEERS SSO ole E IS Transformer N Standard Weatherproof FTC Box Transformer TB1 FTC FTC Board Explosion Proof Flameproof FTC Box Figure 65 Remote FTC Board amp Transformer Previous Version Model FGA 300H X Horizontal Gas Analyzer User s Manual 149 Appendix F Previous Configurations F3 Replacing the FTC Board Fuse The Furnace Temperature Control FTC fuse is located on the FTC board CAUTION To replace the FTC board fuse the power to the FGA 300H X must be disconnected Therefore replace the FTC board fuse and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT This symbol indicates Caution risk of electric shock AN The only tool needed to replace the FTC board fuse is a small screwdriver Refer to Figure 64 on page 147 for local FTC or Figure 65 on page 149 for remote FTC and complete the following steps to replace the FTC board fuse 1 Disconnect the main power to the FGA 300H X
17. 36 Setting Oxygen Trip Point zu re RE EE 34 MOTOS as cde ER RR E NERA UP Y 33 Analog Output Range Adjusting Combustibles Channel 121 Adjusting Oxygen Channel 119 ROGOReIS EEN ex EET ee ee 33 Ancillary Components rai 37 B Blowback System cte ois a AG a 65 C Calibration Combustibles Detector iaa 50 o A ph deh uate hohe ea ea ace 39 Gas Flow Rate gt vow aye wow tenet owes ey 45 Oxygen Sensor x ad Mie c me 45 Plumbing Connections egen tek pear 45 Recommended Gase 43 Cartridge Heaters Replacing 95 CE Mark Compliate oes eite pU cis 145 Combustibles Detector Calibration s 42s abu a eU E ann 50 Re 22 pd ous aua us aec 1 8 Reference Element e Lp EE ERR 71 Replacih uc vane s doen Ue Dae Nera 84 Span Cheeks burrada wd wy beta b ore add 32 Wide did ada 86 Zero Check A s POE AE ESQ ES 52 Common Problems ug d NEE EEG ES 39 Connecting See Part Name Convection Loop s is As 6 Model FGA 300H X Horizontal Gas Analyzer User s Manual Index D Date of Publication 24 lt sa ME AN i Detector Combustibles 1 8 Disconnect Device o ooo ooo ee eee 9 20 Display Combustibles copiar 41 BEE 41 Display Electronics Console DISCO ARI eg Oar o dads Ne Be 5 RT 68 WIDE A A es 23 30 Display Parameter Selecti0N 118 Document Number 1 E EMC Compliance Gs ets tt ig elt he ae 145 Enclosures ea a Aura poseen atr du 1 Environmental Comp
18. 2 Open the hinged cover on the standard Accessory Box or on a standard weatherproof remote FTC box For an explosion proof flameproof remote FTC box loosen the locking set screw on top of the FTC box and using a long screwdriver across the slots provided unscrew the cover from the enclosure 3 Locate the fuseholder on the FTC board Using a small screwdriver remove the spring loaded cover from the fuseholder and discard the old fuse 4 Install a new fuse of the same type and size see Chapter 7 Specifications and reinstall the fuseholder cover 5 Close reinstall the cover on the FTC Box and reconnect the main power to the system The system may now be placed back into service 150 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix F Previous Configurations F 4 Replacing the FTC Board The Furnace Temperature Control FTC board is located either in the Accessory Box or in a remote FTC box The FTC board is a 3 5 x 4 7 in 90 x 120 mm rectangular printed circuit board that maintains a steady sensor furnace temperature in order to ensure accurate operation of the oxygen sensor CAUTION To replace the FTC board the power to the FGA 300H X must be disconnected Therefore replace the FTC board and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT This symbol indicates Caution risk of electric shock GS The only tool nee
19. the stoichiometric interlock is activated faulty combustibles detector or wiring combustibles channel is out of calibration insufficient excess oxygen to support burning of the combustibles combustibles level is greater than 19 990 ppmy To correct this error perform the following checks until the problem is remedied 5 3 1a Check Oxygen Channel The 1 0 combustibles error indicator can be caused by the detection of an open circuit in the oxygen channel which activates the stoichiometric interlock If a blinking error indicator also appears on the oxygen display refer to the Blinking section on page 55 to correct both of these errors If the error is not oxygen related proceed to the next section 5 3 16 Check the Combustibles Detector The out of range combustibles error may also be caused by a faulty or incorrectly wired combustibles detector To check this possibility complete the following steps IMPORTANT This symbol indicates Caution risk of electric shock AN 1 Referto Chapter 2 Installation and verify that the combustibles detector is correctly wired at terminal blocks TB1 in the Accessory Box the remote FTC Box and the Display Console Make sure that none of the wires interconnecting the three terminal blocks are loose or broken 2 Inthe Accessory Box disconnect the common wire from pin 9 of terminal block TB1 and attach one lead of a multimeter to the disconnected wire
20. The mating flange should be positioned so that its bolt holes straddle the vertical and horizontal center lines of the mounting opening see Figure 14 If the unit is ordered with an installed mounting flange the mating flange alignment shown in Figure 14 will ensure that the analyzer is properly oriented In addition make certain that the mating flange is mounted so that the analyzer is vertical and not tilted when it is bolted in place CAUTION The mounting flange on a standard 300H may be rotated readily but rotating the flange on an explosion proof flameproof 300HX may cause the manifold to rotate inside the case Take extreme care to avoid this as the damage so caused to the internal piping is NOT covered under the warranty 18 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 4 Installing the Probe and Probe Sleeve CAUTION Donotuse teflon tape on the threads of the probe components during assembly Teflon tape will melt at the normal probe operating temperature For optimum performance the probe sleeve should extend approximately 1 3 of the way across the flue duct If possible the insertion distance should not be less than 30 cm 1 foot Confirm that the probe and sleeve are the correct lengths Then refer to Figure 15 on page 20 and complete the following steps 1 As shown in Figure 15 on page 20 attach a flange or fixing plate to the rear of the Main Analyzer Unit Orient the fl
21. 182 4 EXT CJC 12 5 EXT SET 12 6 EXT SET 182 7 EXT SSR 182 8 EXT SSR 181 O behind COMBA COMBA SENSOR WIRING Terminal Numbers 12 NEUTRAL EARTH 11 LIVE PHASE 2 Fuse Z Main Analyzer Unit Accessory Box Local FTC Board Behind Panel Model FGA 300H X Horizontal Gas Analyzer User s Manual s a 2 o S5509999 000000000046 Fuse FTC Board p 80 8008 ES WN Standard Weatherproof Remote FTC Box Explosion Proof Flameproof BN Remote FTC Box FICBoard ren FUSE ce Figure 32 FTC Board Fuse and TB1 Locations 63 Chapter 5 Troubleshooting 5 2 1e Check the FTC Board cont 2 The voltages at the two terminal blocks should be the same If they are not check the wiring between the terminal blocks refer to Chapter 2 Installation Then one of the conditions listed in Table 18 should occur Table 18 FTC Output Vol
22. 3 Attach the other lead of the multimeter to pin 10 of terminal block TB1 and record the resistance of the reference element Model FGA 300H X Horizontal Gas Analyzer User s Manual 71 Chapter 5 Troubleshooting 5 3 16 Check the Combustibles Detector cont 4 Move the multimeter lead from pin 10 to pin 7 of terminal block TB1 and record the resistance of the active element 5 Both readings should be between 1800 and 1900 ohms and the difference between them should not exceed 50 ohms Disconnect the multimeter and reconnect the common wire to pin 9 of terminal block TB1 If the proper readings were obtained skip to the next section 6 If either element is shorted 0 ohms or open OL the combustibles detector is defective and must be replaced See Chapter 6 Parts Replacement for instructions 7 Ifthe combustibles detector passes the above checks the combustibles channel may be out of calibration Refer to Chapter 4 Calibration for instructions on calibrating the combustibles detector If the steps in this section do not correct the 1 0 combustibles error consult the factory for assistance 5 3 2 12340 Negative Reading A negative reading on the combustibles display can be caused by incorrect wiring of the combustibles detector or the combustibles circuitry being out of calibration To correct the problem complete the following steps IMPORTANT This symbol indicates Caution risk of electric shock AN
23. WARNING To ensure safe operation of the FGA 300H X it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations for installing electrical equipment All procedures should be performed by trained service personnel Model FGA 300H X Horizontal Gas Analyzer User s Manual 53 Chapter 5 Troubleshooting Table 11 Troubleshooting Guide Error Indicator System Response Description Go To Possible Oxygen Error Indicators 1 alarm relay activated 1 sensor signal exceeds full scale input 2 analog output shows a lack 1000 mV of oxygen on all ranges 2 possible open circuit 3 stoichiometric interlock is 3 possible cold furnace activated Blinking error code E1 PP PP and Normal Reading Alternate the sensor signal has not changed in 15 y MONA minutes the probe may be plugged sensor impedance is high the sensor Blinking Reading no response may need replacement 1 sensor or its wiring shorted no response 2 severe air leak i e cal port open sample system not sealed etc Oxygen Concentration Reads Constant 20 9 Oxygen Reading Above 20 9 error code E4 or no response sensor wiring reversed reading of 55 35 combustibles in the sample Sensor out of calibration Oxygen Reading Too Low no response poor quality reference air Oxygen Reading Too High no response air leak
24. a Loosen the locking set screw on the side of the Sample System Compartment near the bottom and unscrew the enclosure from the base of the unit b Loosen the locking set screw on top of the Accessory Box and using a long screwdriver across the slots provided unscrew the cover from the enclosure WARNING There are extremely hot surfaces in the analyzer If these surfaces are touched serious burns could result Use heat resistant gloves when working within the Main Analyzer Unit IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively AS A 78 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 2 Replacing the Oxygen Sensor Clips The oxygen sensor is connected to the electronics via two contact clips located at the base of the sensor The inner clip is inserted into the end of the oxygen sensor while the outer clip simply snaps around the base of the sensor The following tools are needed to replace the oxygen sensor clips e pliers e wire cutters e wire strippers e crimping tool Power should remain on while replacing the oxygen sensor clips Refer to Figure 35 while completing the following steps Oxygen Sensor Outer Clip gt Inner Clip Figure 35 Oxygen Sensor Clips Model F
25. 1 Refer to Chapter 2 Installation and verify that the combustibles detector is correctly wired at terminal blocks TB1 in the Accessory Box the remote FTC Box and the Display Console 2 Ifthe combustibles detector wiring is correct the combustibles circuitry may be out of calibration Refer to Chapter 4 Calibration for instructions on calibrating the combustibles detector If the steps in this section do not correct the 12340 combustibles error consult the factory for assistance 72 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 3 3 1 0 Negative Out Of Range Indicator The negative out of range error indicator is usually caused by one of the following conditions faulty combustibles detector or wiring combustibles circuitry is out of calibration To correct this error perform the following checks until the problem is remedied IMPORTANT This symbol indicates Caution risk of electric shock AN 1 Referto Chapter 2 Installation and verify that the combustibles detector is correctly wired at terminal blocks TB1 in the Accessory Box the remote FTC Box and the Display Console Make sure that none of the wires interconnecting the three terminal blocks are loose or broken 2 Inthe Accessory Box disconnect the common wire from pin 9 of terminal block TB1 and attach one lead of a multimeter to the disconnected wire 3 Attach the other lead of the multimeter to pin
26. 2 Remove the four screws which support the front panel 3 Rotate the Front Panel Assembly clockwise slightly to clear the flange and carefully pull it straight out of the enclosure as far as the attached leads will allow 75W Heater Thermostat Thermostat 150W Heater _75W Heater 150W Heater LEPEEEEEEEEEEEPEEELELELELELEL CEEEFEEEEEEEEEFEEEEETETETFEEETEETI eo UI Front Panel Assembly top view _ TB4 lt behind T COMBUS o2 o2 4RIDTTC 3RID TC SCREEN i5 202mV Q 102mv OXYGEN SENSOR amp RTD WIRING TOMER INTERNAL 14 FURNACE 12 NEUTRAL EARTH 11 LIVE PHASE Es Figure 40 Main Accessory Box TB4 Location Model FGA 300H X Horizontal Gas Analyzer User s Manual 89 Chapter 6 Parts Replacement 6 2 7 Replacing the Sensor Furnace The sensor furnace maintains the oxygen sensor at a stable temperature to ensure the accuracy of the percent oxygen readings and to extend the useful life of the oxygen sensor The sensor furnace is located in the Sample System Compartment and is easily replaced Replacement of the sensor furnace requires the following tools open end wrenches 2 torque wrench e screwdriver digital multimeter
27. 5 2 70 Check for Plumbing Leaks 1 Remove the Sample System Compartment cover in order to allow uncontaminated reference air to enter the unit 2 Ifthe oxygen reading drops in Step 1 above tighten all fittings by 1 8 turn and replace the Sample System Compartment cover If the oxygen reading gradually increases repeat Step 1 CAUTION Do not tighten fittings more than 1 8 turn at a time 5 2 70 Check the Oxygen Sensor Temperature If the oxygen sensor is below its normal operating temperature the mV output will be too low and the percent oxygen reading will be higher than expected Proceed as follows 1 The easiest way to check the sensor temperature is to calibrate the oxygen sensor as described in Chapter 4 Calibration The calibration procedure includes instructions for adjusting the sensor furnace temperature if necessary If the problem has not been resolved by the steps in this section contact the factory for assistance Note Although the E2 sensor aging and E3 probe plugging error codes have been defined they have not yet been implemented 70 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 3 Combustibles Errors The following is a list of the possible combustibles error indicators If an unlisted error occurs contact the factory for assistance 5 3 1 1 0 Out Of Range Indicator The out of range error indicator is usually caused by one of the following conditions
28. E
29. E6 VTEMP E1 ARTN TB2 1 RTD TC TB2 2 RTD TC TB2 3 EXT CJC TB2 4 EXT CJC TB2 5 EXT SET TB2 6 EXT SET TB2 7 EXT SSR TB2 8 EXT SSR FURNACE HEATER BLOCK CCW TO TEMP ADJ INCREASE CW TO INCREASE T B ll OXYGEN TEMPERATURE behind a Mains TB3 FUSE 95x20mm T2 5A 12 NEUTRAL EARTH 11 LIVE PHASE a ve CUSTOMER TB1 Terminal Numbers 300H Accessory Box Figure 19 Standard Display and Accessory Box Terminals for Local Wiring Model FGA 300H X Horizontal Gas Analyzer User s Manual 27 Chapter 2 Installation 2 5 6 Wiring a 300H X with Remote FTC For units that have the FTC circuit board mounted in a Remote FTC Box complete the following sections Interconnection Diagram Figure 22 on page 32 has been included for help in making the proper connections Wiring diagrams Figure 65 on page 149 and Figure 67 on page 157 which correspond to earlier versions of the 300H FGA can be found in Appendix F 2 5 6a Connecting the Analyzer to the Remote FTC Box Make wiring connections from terminal blocks in the Remote FTC Box to terminal blocks in the Accessory Box the smaller box which is part of the Main Analyzer Unit Refer to Figure 20 on page 29 and Table 3 for the terminal block locations and the proper pin connections Table 3 Mai
30. The front panel of the Display Console shows both the oxygen reading and the combustibles reading when applicable The combustibles display shows total combustibles which is normally a combination of CO and H The oxygen display is factory set to show the ordered parameter However the keypad may be used to display all other available parameters which are listed in Table 9 along with their corresponding keys All of the parameters listed in Table 9 can be displayed by pressing the appropriate key on the keypad The selected parameter is displayed until the key is released Note These parameters may be selected as the default display using the internal rotary switch S2 See Chapter 2 Installation for more details Table 9 FGA 300H X Keypad Parameters Key Parameter Description This parameter with respect to the total flue gas volume supplements Equivalent Combustibles the combustibles measurement in excess fuel situations This parameter with respect to fuel only detects poor combustion or Excess Fuel controls conditions when fuel is deliberately in excess such as in reducing atmospheres This key displays the amount of oxygen in excess of the stoichiometric Percent Oxygen quantity This is the only accurate method for properly setting the air fuel ratio This key displays the raw oxygen sensor millivolt output which indicates Oxygen Sensor Millivolts the condition of the oxygen sensor This parameter
31. Available Options Some of the available options for the 300H X Flue Gas Analyzer are listed below Remote logarithmic meter e Dual alarm contacts for oxygen or combustibles e Flameproof analyzer CENELEC EEx d IIB T3 ISSEP cert 01E 103 1315 X Note Asa special consideration for certification the flue gas can not generate an explosive atmosphere e Sample probe lengths up to 1 4 m e Analyzers for sampling at flue gas temperatures up to 1 700 C 3 092 F and or flue gas acid dew points higher than 180 C 356 F Analyzers for ambient temperatures higher than 70 C 158 F Consult the factory for additional information Model FGA 300H X Horizontal Gas Analyzer User s Manual 111 Chapter 7 Specifications 7 5 Ordering Information The information below shows how the FGA 300H Part Number is configured from the options specified FGA300H Table 22 FGA 300H Weatherproof Ordering Information CATEGORY Oxygen Sensor OPTIONS 0 None 1 Standard oxygen sensor type 1 2 Oxygen sensor for stoichiometric combustion type 2 Combustibles Detector 0 None 1 Standard combustibles detector with flowmeter 1 100 VAC 2 110 120 VAC 3 220 VAC 4 240 VAC Furnace Controller Enclosure 0 No furnace temperature control card Spares orders only 1 Local furnace temperature control 3 Remote Weatherproof FTC enclosure IP6
32. C the above equation becomes E mV 48 273 e 1og DC P2 The voltage drop across the zirconium oxide sensor as calculated from the Nernst equation is then sent to the linearizer circuit The circuit produces a linear analog output that represents the percentage of oxygen in the flue gas and this signal is available as a recorder output at pins 1 and 2 of terminal block TB2 on the Display Console circuit board For convenience the standard Nernst equation for the FGA 300H X above has been converted into a graphical format Use this graph see Figure 60 on page 139 to quickly correlate the analog output voltage reading with the corresponding oxygen percentage at the operating temperature of the unit 138 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix C The Nernst Equation 0 0001 Oxygen Concentration Figure 60 Oxygen Sensor Output at 700 C Model FGA 300H X Horizontal Gas Analyzer User s Manual 139 no content intended for this page 140 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix D Wiring Diagrams and Circuit Boards Appendix D Wiring Diagrams and Circuit Boards Model FGA 300H X Horizontal Gas Analyzer User s Manual 141 Appendix D Wirin
33. CAUTION To replace the sensor furnace the power to the FGA 300H X must be disconnected Therefore replace the sensor furnace and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively AD A 6 2 7a Removing the Old Sensor Furnace Complete the following steps in the order given to remove the old sensor furnace 1 Disconnect the main power to the FGA 300H X 2 Remove the Sample System Compartment cover as described in the Removing the Cover section on page 78 3 Access terminal block TB4 by Moving the Front Panel Assembly on page 89 4 Disconnect the sensor furnace power wires from TB4 pins 12 and 13 in the Accessory Box see Figure 40 on page 89 5 Remove the temperature sensor located on the top of the sensor furnace as described in the Replacing the Temperature Sensor section on page 87 Place the temperature sensor aside for later reinstallation 6 Refer to Figure 41 on page 91 and place one open end wrench on the flat surface machined into the piping just above the sensor furnace Place a second open end wrench on the nut directly above the first wrench 90 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 7a Removing the Old Sensor Furnace cont 7 Note The wrenches should be paralle
34. Choices 33 Winge PA A uA EE 33 Reference AMES A Aa 22 Replacing See Part Name Return Policy saa a Si 165 RTD Replacing 2a key SAAR CUEVA 87 Testing oed cea e t A ae 57 S Safety Auxiliary Equipment ooo ooooooo 111 General ISsues EE 111 Personal EquipMeNt oo oooooooo o o 111 Sample Gas Contamination oo oooooooo 69 Sample System sE Beate En 2 11 Sensor Furnace Adjusting Temperature 49 155 Checking Temperature 57 Replacing euch wean AA eee ACE 90 A et Cte ete ees 94 Sensor Ode Seta 1 6 Shroud NEE 14 Site tee 9 20 SeleclloDa EEN 17 Spare Parts List otek eae ees 106 107 Specifications Combustibles dewey aa ads 110 General sonst II eeu EE 109 OXY O kana RS ERG ial RR 110 Switches Display Electronics Console lusus 23 Selecting Display Parameter 117 Selecting Fuel Types sos zie Tuus dx IAS 117 Model FGA 300HIX Horizontal Gas Analyzer User s Manual 7 Temperature Heater Block AS a SE 6 Sensor Eatflace y ios ra oe ERE Tu 6 Sensor Types ha ee SEA AE A 57 Thermocouple IRE ACH o noo as Sak Retiree seen Ris Ee 87 EEN 59 Thermostat Replacing 52 207 3 ate 97 Transformer Replacing ag osx REA Re OER EAR 154 TESNE Eoo onset ied e ie Ree A nulo dri t Aa 148 V Voltage Line Iput ed ves ev RR 16 W Warm Up Time sos x eer APP RUE ASIE N 39 Warranty iade bUkG a pA a E EA TR TEN 165 WEEE Direcliye c duet dde iv Wiring See Part Name Model FGA 300
35. FGA300HX Horizontal Flue Gas Analyzers FGA300V and FGA300VX Vertical Flue Gas Analyzers FGA300D Display Unit FGA311 In Situ Flue Gas Oxygen Analyzer to which this declaration relates are in conformity with the following standards e EN 61326 1 2006 Class A Table 2 Industrial Locations e EN 61326 2 3 2006 e EN 61010 1 2001 Overvoltage Category II Pollution Degree 2 following the provisions of the 2004 108 EC EMC and 2006 95 EC Low Voltage Directives The units listed above and any ancillary equipment supplied with them do not bear CE marking for the Pressure Equipment Directive as they are supplied in accordance with Article 3 Section 3 sound engineering practices and codes of good workmanship of the Pressure Equipment Directive 97 23 EC for DN 25 A A Af pid i Billerica August 2010 Issued Mr Gary Kozinski Certification amp Standards Lead Engineer Se CE TUV Customer Support Centers U S A The Boston Center 1100 Technology Park Drive Billerica MA 01821 U S A Tel 800 833 9438 toll free 978 437 1000 E mail sensing ge com Ireland Sensing House Shannon Free Zone East Shannon County Clare Ireland Tel 353 0 61 470291 E mail gesensingsnnservices ge com An ISO 9001 2008 Certified Company www ge mcs com en about us quality html www ge mcs com 2011 General Electric Company All rights reserved Technical content subject to change without notice 910 078 Rev
36. Flowmeter 300HX 1781 505 Plug 8mm Serto 1420 619 Flow Shield 1781 525 Internal Calibration Tube 300H 1781 511 Calibration Stub 6mm 1781 504 ble er e e er er er e e kal er e er a e e e e rs rm rm rf er tal rm rir Bulkhead Fitting Cal Port Model FGA 300H X Horizontal Gas Analyzer User s Manual 107 Chapter 6 Parts Replacement Ech no content intended for this page 108 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 7 Specifications Chapter 7 Specifications 7 1 General Specifications Response Time 20 seconds to within 90 of a step change Sample Probe Length Standard 0 6 m 24 in high temperature resistant steel Optional 1 0 m 39 in 1 4 m 55 in or special lengths Sample Dew Point 180 C 356 F maximum higher dew point version available Ambient Temperature Analyzer 25 to 70 C 13 to 158 F higher temperature version available Digital Display Unit 10 to 50 C 14 to 122 F Power Requirement Maximum on Start up 10 400W max 115 230 VAC 50 60 Hz dropping to 250W when at temperature Fuses Anti Surge T Type 5x20 mm FTC Board 2 5 A Digital Display Board 200 mA 115 VAC 100 mA 230 VAC Warm Up Time Meets specified accuracy within one hour Area Classification for FGA 300H 112 G EEx d IIC T4 ISSeP 04ATEX078X Note Asa special consideration for certification th
37. For other gas mixtures calculate the expected oxygen sensor voltage output with the following equation E 20 9 E700 mV 48 273 x lel 02 in Cal asl 2 Note For a FGA 300H X operating at any other temperature refer to Appendix C The Nernst Equation for details on converting the known oxygen concentration into the expected oxygen sensor millivolt output reading Model FGA 300H X Horizontal Gas Analyzer User s Manual 47 Chapter 4 Calibration 4 3 2 Calibration Check cont 48 Z ES VSET CLE gt ES VTEMP Co ELARTN HS 9 10 E SCR OP 182 1 RTO TC TB2 2 RTD TC 182 3 EXT CJC TB2 4 EXT CJC 182 5 EXT SET TB2 6 EXT SET 182 7 EXT SSR TB2 8 EXT SSR 181 FL behind FUSE 5x20mm T2 5A 12 NEUTRAL EARTH 11 LIVE PHASE 7 COMBA compa m S COMBR Q HH rouen Zo 02 7COM 9COM 10 COM SCR SENSOR WIRI a CUSTOMER U iN o m o Dy TB1 Terminal Numbers Temperature Adjust RA ER Main Analyzer Unit Accessory Box Local FTC Board behind panel mA mas cH UJ GECKEN aoa 2808 FTC Board
38. Furthermore the resistances of the two elements should be within 50 ohms of each other while reading the sample gas If these conditions are not met consult the factory for assistance IMPORTANT This symbol indicates Caution risk of electric shock AN The resistances are checked on pins 5 7 of terminal block TB1 in the Display Console See Figure 27 on page 51 for the location of TB1 and the calibration potentiometers To check the resistances complete the following steps Disconnect the wire from pin 6 of terminal block TB1 Attach one lead of a multimeter to the disconnected pin 6 wire Attach the other lead of the multimeter to pin 5 of terminal block TB1 and record the resistance value Move the multimeter lead from pin 5 to pin 7 of terminal block TB1 and record the resistance value gu E A E Both readings should be between 1800 and 1900 ohms and the difference between them should not exceed 50 ohms If this is not the case contact the factory for assistance 6 Disconnect the multimeter and immediately reconnect the wire to pin 6 of terminal block TB1 50 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 4 Calibration b seeeeeeeeeeee Seeeeeeeeeeee S2 1 DISPLAY FUEL ooo
39. HO GIYINOSY HOLIMS LOINNODSIC SNIVIA XHOO LON AINO HOOS 310N LINA 83ZA IVNV NIVIA D Jl AIdANS E SEI JOVNUN 21 281 31ON 33S E ER SE YOSNIS NIDAXO LAdLNO aWod Wav 1V 8WO2 c81 1 29 v 81 S 8l 9 79 el 30N383338 OT NORWOS 61 30123130 SIISILSNEWOD SLNdLNO 4vV38 LV STVNIIAS3 L ddd q00 S341N39 WWQ9X09 SJIYLNI LdN t7 XZ 59d S 91 911 p x33 NMOHS LON dX3 000 SUN SI41N39 WW29 SAIYLNA WWOZD Xt 99dI d3M 0002 A E mr 00 Salas EE ZL S39 1N39 WWOS SAIN LNA WWOZD xe HOOS V93 Jez euy sep an Figure 18 Interconnection Diagram for Standard 300H FGA with Local FTC 25 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 5 5 Wiring a 300H X with Local FTC In most instances the FTC circuit board is mounted in the Accessory Box which is attached to the bottom of the Main Analyzer Unit For these units complete the following section The 300H standard weatherproof model is wired at the factory according to the specifications in your order All that is required is to wire the Accessory Box terminal block TB1 to the Display terminal block TB 1 and then connect both to power supplies 2 5 5a Connecting the Display Make wiring connections from the display terminal block TB1
40. Point A x 100 60 and set Switch 4 to position 6 O Table 8 Rotary Switch S4 Settings Alarm Trip Point Switch Position as of Full Scale Range o 1 2 3 4 5 6 7 8 9 34 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 5 8 Connecting Alarms cont S3 ALARM ANALOG d D Figure 23 300D Display Circuit Board Note For units fitted with the previous
41. Sleeve cont Mounting Surface N Gasket Hardware 7 N N Hardware d Probe Sleeve N Heater Block Approx 3 mm We Probe 12 in Manifold shown with other components removed for clarity Mating Flange 1 Mounting Flange 1 3 of diameter im or 30 60 cm 1 2 ft whichever is less Figure 15 Sample Probe Assembly 2 5 Installing the System Note Ifmore than one analyzer system is being installed be aware that each system is a matched set i e each Remote FTC Box probe probe sleeve and Display Console must be matched to a specific analyzer Refer to tags on the box probes sleeves displays and analyzers in order to match the units correctly IMPORTANT For compliance with the European Union s Low Voltage Directive 73 23 EEC the standard 300H requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit Because the sensor furnace power feed in a remote FTC Box must also be interrupted a 4 pole disconnect device is required for units so equipped This does not apply to the flameproof 300HX IMPORTANT This sy
42. V9Y S381N3O UJUJ 9xe9 S3IH 1N3 LAN 7 X9 S9dl S 91 Dll p x33 dX3 213 S341N39 WWSS S3IH LN3 LdN Z TX S9dl S SL 911 P X33 yO XHOO VOI ES n Jazijeuy sep anid ith Remote FTC in Analyzer w iagram for Ma ionD Interconnect igure 22 F Model FGA 300H X Horizontal Gas Analyzer User s Manual 32 Chapter 2 Installation 2 5 7 Connecting Recorders The 300D Display Console provides a pair of outputs for connecting a recorder to the system Make the connections to terminal block TB2 on the 300D Display circuit board The recorder output mode is set to either current or voltage at the factory prior to shipment Use Table 6 to make the proper connections and refer to Figure 21 on page 31 for the terminal block location on the 300D Display circuit board Table 6 Recorder Connections Output Variable 300D Display Pin TB2 Oxygen Oxygen Combustibles Combustibles The scale for the outputs is either a zero based linear output 0 20 mA 0 10 V or an offset linear output 4 20 mA 2 10 V as specified when ordered To change the preset output range see Appendix A Rotary Switch Settings 2 5 8 Connecting Alarms In order to make alarm connections a Display Console is required There is one alarm for the oxygen channel and one for the combustibles channel Once the alarms are connected the alarm trip poin
43. and the combustibles detector This completes the replacement of the FTC board Model FGA 300H X Horizontal Gas Analyzer User s Manual 151 Appendix F Previous Configurations F5 Replacing a Local Transformer In a local FTC setup the sensor furnace power transformer is located behind the FTC board in the Accessory Box Its purpose is to convert the line voltage to the 80 VAC required for proper operation of the sensor furnace CAUTION To replace the transformer the power to the FGA 300H X must be disconnected Therefore replace the transformer and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation The following items are needed to replace the transformer e A nutdriver or similar tool e A screwdriver e adigital multimeter IMPORTANT This symbol indicates Caution risk of electric shock AN Refer to Figure 64 on page 147 and complete the following steps to replace the transformer 1 Disconnect the main power to the FGA 300H X 2 Open the hinged cover on the Accessory Box 3 Remove the connector from the 12 pin terminal block TB1 on the FTC circuit board 4 Remove the four hex nuts and washers located in the corners of the FTC board and lift the FTC board out of the enclosure 152 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix F Previous Configurations F 5 10 11 12 13 14 15 16 17 Replacing
44. as close to the oxygen sensor as possible without touching it Place the negative lead of the multimeter on the outer clip the clip around the base of the oxygen sensor See Figure 29 on page 57 for the location of the clips 3 Ifthe measurement indicates an open loop OL adjust the clips to make certain they are making good contact with the oxygen sensor and take another reading If an open loop is still measured the oxygen sensor is defective and must be replaced 5 2 1d Check the Sensor Furnace If the sensor furnace operating temperature was too low the troubleshooting sequence should resume here IMPORTANT This symbol indicates Caution risk of electric shock AN 1 Disconnect the sensor furnace leads from pins 12 and 14 of terminal block TB3 in the Accessory Box 2 Using a digital multimeter measure the resistance across the disconnected sensor furnace leads One of the conditions listed in Table 16 should occur Table 16 Sensor Furnace Resistance Readings Resistance Reading Recommended Action 63 70 ohms The sensor furnace is good proceed to the FTC board check Check the wires from the Accessory Box to the ceramic block to see if they are broken or loose open loop OU If the wiring is good the sensor furnace is defective and must be replaced refer to Chapter 6 Parts Replacement Model FGA 300H X Horizontal Gas Analyzer User s Manual 61 Chapter 5 Troubleshooting 5 2 1d Check the Sensor Furnac
45. blocks and usually a local FTC board see Figure 8 Front View Calibration Gas Port Flue Gas Analyzer Series 300 WARNING SURFACES ARE VERY HOT KEEP ANALYZER ENERGISED A Conduit Holes Shroud Probe Sleeve Mounting Flange Es optional Side View y PS Sample System Compartment gt Optional Aspirator Port Accessory Box Figure 8 Standard Weatherproof Model 10 Model FGA 300HI X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 2 2 Sample System The sample system consists of a sampling inlet tube a heater block with thermostat an oxygen sensor a sensor furnace a convection loop to circulate the sample gas and if ordered a combustibles detector see Figure 9 Convection Loop Sensor Furnace Cr Combustibles Detector optional Cartridge Heater N Thermostat gt Heater Block Oxygen Sensor Figure 9 Standard Sample System Model FGA 300H X Horizontal Gas Analyzer User s Manual 11 Chapter 2 Installation 2 2 3 Remote FTC Box For explosion proof flameproof units and for installations where the ambie
46. extraction and use of natural resources for its production It may contain hazardous substances that could impact health and the environment In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources we encourage you to use the appropriate take back systems Those systems will reuse or recycle most of the materials of your end life equipment in a sound way The crossed out wheeled bin symbol invites you to use those systems If you need more information on the collection reuse and recycling systems please contact your local or regional waste administration Visit http www ge mcs com en about us environmental health and safety 1741 weee reg html for take back instructions and more information about this initiative iv Model FGA 300H X Horizontal Gas Analyzer User s Manual Contents Chapter 1 General Information 1 1 1 2 1 3 Wi NE 1 Display CONS Ole e T T 5 Principles of Operations osko A A A Moi o compu ud 6 132k ele ee e He EE e EE 6 1 3 2 Platinum Catalyst Combustibles Detector s cac cue sa Aare EE wee Nene EE i on 8 Chapter 2 Installation XMEG I occ 9 2 2 Configuration OPU ONS Ee POR pr FECHAS PESCE LA S saan aa 10 2 2 1 Standard Weatherproof Enclosure isse rre Cea a RS der PETERE Tae ley FER UE E EEG NS 10 Ze cames SIBI do RS ENDO t ML EE EEN 11 22S Remote FIC EEN 12 2 2 4 Explosion Proof Flameproof ere EE EE 13 2 25 cd al A A O dti se
47. is configured from the options specified FGA300HX Table 23 FGA 300HX Explosion Proof Ordering Information CATEGORY OPTIONS 0 None Oxygen Sensor Standard oxygen sensor type 1 2 Oxygen sensor for stoichiometric combustion type 2 Combustibles 0 None Detector 1 Standard combustibles detector with flowmeter 1 100 VAC 2 110 120 VAC 3 220 VAC 4 240 VAC 0 None Furnace 3 Remote Weatherproof FTC enclosure IP65 Controller 4 Remote Flameproof FTC enclosure II 2 G EEx d IIC Enclosure 5 304 SS remote Weatherproof FTC enclosure IP65 6 Display unit S Special 2 DN80 PN16 flange C S mounting 3 ANSI 3 300 Ib flange C S mounting 4 Two flanges with gasket DN80 PN16 C S for mounting Mounting 5 Two flanges with gasket ANSI 3 300 Ib C S for mounting 6 ANSI 4 150 lb flange C S mounting 7 Two flanges with gasket ANSI 4 150 Ib C S for mounting S Special 0 Diffusion convection based sampling Aspirator 1 Aspirator included S Special External Port 0 6mm external port connections Connections 1 1 4 external port connections 0 None 1 Flowmeter and valve for calibration port 2 Tropicalized electronics S Special Special Temperature 0 Standard temperature setting 700 C Control Setting S Special temperature setting 770 812 C please specify N
48. operating temperature of the oxygen sensor the atmospheric reference oxygen is electrochemically reduced at the inner electrode and the resulting oxygen ions seek to equalize with the lower oxygen concentration on the sample side of the cell by migrating through the porous ceramic toward the outer electrode At the outer electrode they give up electrons to become oxygen molecules again and are swept away by the sample gas flow The lower the concentration of oxygen in the flue gas sample the greater the rate of ion migration through the ceramic and the higher the cell voltage due to electron exchange at the electrodes The cell voltage rises logarithmically as the amount of oxygen in the flue gas falls allowing the accurate measurement of very low levels of excess oxygen in the flue gas Model FGA 300H X Horizontal Gas Analyzer User s Manual 7 Chapter 1 General Information 1 3 2 Platinum Catalyst Combustibles Detector The combustibles detector consists of two platinum thermistors mounted side by side in the sample stream One thermistor the active element is used to detect react partial combustion products while the other thermistor the reference element provides a baseline The active element is coated with a black platinum catalyst and the reference element has a white inert surface As the sample gas passes over the active element the platinum catalyst causes any combustibles to burn in the presence of excess oxygen thereby r
49. optional recorders and alarms are shown later in this section Refer to Appendix F Previous Configurations for earlier versions of the FGA 300H X WARNING In order to meet CE Mark requirements all cables must be installed as described in Appendix E CE Mark Compliance IMPORTANT For compliance with the European Union s Low Voltage Directive 73 23 EEC the standard 300H requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit Because the sensor furnace power feed in the remote FTC Box must also be interrupted a 4 pole disconnect device is required This does not apply to the flameproof 300HX WARNING To ensure safe operation of the FGA 300H X the unit must be installed and operated as described in this manual Also be sure to follow all applicable local safety codes and regulations for installing electrical equipment All procedures should be performed by trained service personnel 24 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 310SNOO S2INO3S 12313 AVIASIO S1300W d 1331208 13NVd 931 OL 0381M AYOLOV3 SISSVHI D Adans 1181 S EL SNIVW LAdLNO N39AXO Wav 1V N39AXO l e8l CH l 81 c cd 81 SOIMLIWVNVd 39 Ad a3riddns LON LNSWSYINOSY AYVN 32 GAT T OTOT 931 T OTOT9 N3 HLIM JONVNdWOD
50. rotary switches located on its printed circuit board which are used to set fuel type Switch 1 e display parameter Switch 2 analog output range Switch 3 e alarm level Switch 4 These switches have been pre set at the factory according to the customer s specifications however they can be reset as required To reset the rotary switches see Appendix A Rotary Switch Settings IMPORTANT This symbol indicates Caution risk of electric shock AN WARNING The above electric shock symbol is also applied next to screws that secure components essential to the double insulation requirements of the EN61010 standard Removal of these screws and or components may result in a safety hazard Model FGA 300H X Horizontal Gas Analyzer User s Manual 23 Chapter 2 Installation 2 5 4 Making Wiring Connections 1 Local FTC To wire units with the FTC circuit board in the Main Analyzer Accessory Box refer to page 26 and complete the following steps Wire the 300H X Accessory Box to the 300D Display Console Connect power to both the 300H X and the 300D Display Console 2 Remote FTC To wire units with the FTC circuit board in a Remote FTC Box refer to pages 2 20 through 2 24 and complete the following steps Wire the 300H X Accessory Box to the Remote FTC Box Wire the 300D Display Console to the Remote FTC Box Connect power to both the Remote FTC Box and the 300D Display Console Additional connections for
51. s Manual Chapter 3 Operation Chapter 3 Operation 3 1 Overview The FGA 300H X is an easily operated monitoring device However before using the analyzer allow it to warm up for at least one hour three hours if possible In addition make sure all electrical and mechanical connections have been completed before power is applied This chapter includes discussions of the following topics Preventing Common Problems e Powering Up the System e Taking Measurements e Using the Display and Keypad Calibration of the analyzer should be checked once or twice a week for the first month of operation and then once every two or three months Units with combustibles detectors need more frequent checking than those with oxygen sensors only See Chapter 4 Calibration for the correct procedures WARNING To ensure safe operation of the FGA 300HIX it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations for installing electrical equipment 3 2 Preventing Common Problems Because of the complex techniques required to monitor flue gases some basic precautions must be observed Failure to observe these simple procedures is often the cause of some common problems with the FGA 300H X operation Compliance with the following instructions will help to eliminate such problems 1 Never use thread sealant on any joints in the sample flow path Thre
52. temperature sensor wires to the location of terminal block TB1 in the Accessory Box 9 Connect the temperature sensor wire leads to pins 3 and 4 of terminal block TB1 Polarity is not important for an RTD type sensor but the TC type must have the positive yellow lead connected to pin 3 and the negative red lead connected to pin 4 10 Install the Sample System Compartment cover by completing the steps in the Removing the Cover section on page 78 in reverse order and close the Accessory Box cover 11 Reconnect the main power to the unit and recalibrate the oxygen sensor as described in Chapter 4 Calibration Clamp Leads RTD Sensor ND y Sensor Furnace Figure 39 Temperature Sensor Location 88 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 6 Moving the Front Panel Assembly The following three procedures Replacing the Sensor Furnace Replacing the Cartridge Heaters and Replacing the Thermostat each require access to terminal block TB4 which is mounted on the back of the Front Panel Assembly To make TB4 accessible refer to Figure 40 and use the following procedure Note The remote version Accessory Box is shown in Figure 40 The TB4 location is the same for a local Accessory Box 1 Open the hinged cover on the Accessory Box
53. the FTC board in the remote FTC Box Its purpose is to convert the line voltage to the 80 VAC required for proper operation of the sensor furnace CAUTION To replace the transformer the power to the FGA 300H X must be disconnected Therefore replace the transformer and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation The following items are needed to replace the transformer e A nutdriver or similar tool e adigital multimeter IMPORTANT This symbol indicates Caution risk of electric shock AN Refer to Figure 65 on page 149 and complete the following steps to replace the transformer 1 Disconnect the main power to the FGA 300H X 2 Open the hinged cover on the standard weatherproof FTC box For an explosion proof flameproof FTC box loosen the locking set screw on top of the FTC box and using a long screwdriver across the slots provided unscrew the cover from the enclosure 3 Remove the four hex nuts and washers from the old transformer 4 Move the old transformer aside do not disconnect any wires yet and place the new transformer into the remote FTC Box 5 Disconnect the leads from the old transformer one at a time and connect the corresponding lead from the new transformer in its place until all of the new leads have been connected Verify that the new transformer leads are properly connected by referring to Figure 68 on page 158 Remov
54. the problem Use of a blowback system contact the factory for assistance should clear the analyzer and restore proper operation 2 Ifthe analyzer reading recovers promptly dead space is the likely problem Furnace internal structures can cause dead spaces that are not evident from an external examination Often the installation of a longer probe may solve a dead space problem However it may sometimes be necessary to relocate the analyzer to a more suitable installation site If any situations not covered in this chapter are encountered contact the factory for assistance Model FGA 300H X Horizontal Gas Analyzer User s Manual 75 Chapter 5 Troubleshooting no content intended for this page 76 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement Chapter 6 Parts Replacement 6 1 Overview The FGA 300H X is designed to enable easy and quick servicing if necessary This chapter describes the replacement of major and minor components of the 300H X However before actually replacing any component carefully read the complete instructions to become familiar with the procedures Each section of this chapter gives a list of the equipment needed to complete the component replacement Please make sure that any necessary replacement parts are on hand before dismantling the analyzer In addition the first paragraph of each section gives a description of the function and location of the part to be rep
55. version of the 300D printed circuit board see Appendix F Previous Configurations for the layout of this circuit board Model FGA 300H X Horizontal Gas Analyzer User s Manual 35 Chapter 2 Installation 2 5 8 Connecting Alarms cont 2 5 8b Setting the Alarm Trigger Mode After setting the alarm trip point the alarm trigger mode must be set The oxygen alarm can be set for either high or low operation 2 To set the alarm trigger mode complete the following steps a Locate jumper W1 on the 300D Display printed circuit board See Figure 23 on page 35 b Set jumper W1 to either of the following settings for the desired alarm trigger mode Low Alarm install jumper in 1 2 position High Alarm install jumper in 2 3 position A high alarm will activate when the oxygen measurement goes over the alarm trip point and a low alarm will activate when the oxygen measurement goes below the alarm trip point 2 5 8c Setting the Combustibles Alarm Trip Point The combustibles alarm trip point is set by using the jumpers and potentiometers on the 300D Display printed circuit board Complete the following steps and refer to Figure 23 on page 35 to set the combustibles alarm trip point 1 Move the jumper at location W101 from its original 1 2 position to position 2 3 2 Adjust potentiometer R113 until the desired alarm trip point in combustibles ppmy appears on the digital display 3 Set the jumper at location W102 to either of the
56. 0 10 V 0 596 4 20 mA 2 10 V 0 10 0 20 mA 0 10 V 0 10 4 20 mA 2 10 V 0 15 0 20 mA 0 10 V 0 15 4 20 mA 2 10 V 0 20 0 20 mA 0 10 V 0 20 4 20 mA 2 10 V 0 25 0 20 mA 0 10 V 0 25 4 20 mA 2 10 V VD 10 o0o c c1 AININ e Use Table 31 to determine the switch S3 setting if switch S2 is set to position 3 Table 31 Switch S3 Settings S223 Analog Output Range 0 0 8 2 0 0 20 mA 0 10 V 1 0 8 2 0 4 20 mA 2 10 V Use Table 32 to determine the switch S3 setting if switch S2 is set to position 4 Table 32 Switch S3 Settings S2 4 Analog Output Range 0 7 0 14 1 0 20 mA 0 10 V 1 7 0 14 1 4 20 mA 2 10 V Use Table 33 to determine the switch S3 setting if switch S2 is set to position 5 Table 33 Switch S3 Settings 52 5 Analog Output Range 0 0 1000 mV 0 20 mA 0 10 V 1 0 1000 mV 4 20 mA 2 10 V 120 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix A Rotary Switch Settings A 5 Adjusting the Combustibles Channel The following two adjustments can be made to the combustibles channel of the Display Console e Setting the scale type zero based or offset e Setting the Zero and Full Scale Values A 5 1 Setting the Scale Type Each unit is shipped with the analog outputs set up as specified at the time of purchase However the analog outputs can be changed to be either a zero based or offset scale using the following p
57. 10 of terminal block TB1 and record the resistance of the reference element 4 Move the multimeter lead from pin 10 to pin 7 of terminal block TB1 and record the resistance of the active element 5 Both readings should be between 1800 and 1900 ohms and the difference between them should not exceed 50 ohms Disconnect the multimeter and reconnect the common wire to pin 9 of terminal block TB1 If the proper readings were obtained skip to the next section 6 If either element is shorted 0 ohms or open OL the combustibles detector is defective and must be replaced See Chapter 6 Parts Replacement for instructions 7 Ifthe combustibles detector passes the above checks the combustibles circuitry may be out of calibration Refer to Chapter 4 Calibration for instructions on calibrating the combustibles detector If the steps in this section do not correct the 1 0 combustibles error contact the factory for assistance Model FGA 300H X Horizontal Gas Analyzer User s Manual 73 Chapter 5 Troubleshooting 5 3 4 Low Combustibles Reading but Correct Oxygen Reading If the Low Combustibles Reading error condition occurs check the following possible causes the combustibles detector was improperly installed or is physically damaged the combustibles detector has lost sensitivity due to aging e the combustibles detector was calibrated at too low a flow rate To correct this error condition complete the following s
58. 5 5 304 SS remote Weatherproof FTC enclosure IP65 S Special Mounting 1 1 1 2 male NPT thread mounting 2 DNSO PN16 flange C S mounting 3 ANSI 3 300 Ib flange C S mounting 4 Two flanges with gasket DN80 PN16 C S for mounting 5 Two flanges with gasket ANSI 3 300 Ib C S for mounting 6 ANSI 4 150 lb flange C S mounting 7 Two flanges with gasket ANSI 4 150 Ib C S for mounting S Special Aspirator 0 Diffusion convection based sampling 1 Aspirator included S Special External Port Connections 0 6mm external port connections 1 1 4 external port connections Special 0 None 1 Flowmeter and valve for calibration port 2 Tropicalized electronics S Special Temperature Control Setting 0 Standard temperature setting 700 C S Special temperature setting 770 812 C please specify Note Option J 1 is not required for units with combustibles detectors as the flowmeter is supplied with option B 1 Option J 1 is available for Oxygen only units Note Oxygen sensor types Type 1 is a plasma sprayed cell and is the standard cell Type 2 is a coated plasma sprayed cell intended for applications where percent levels of CO are expected 112 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 7 Specifications 7 5 Ordering Information cont The information below shows how the FGA 300HX Part Number
59. ANT Do not disconnect any other leads at these terminals 7 Remove the old thermostat by pulling it out of the heater block 6 2 9a Installing the New Thermostat 1 A ww P Y bh Brush a thin coat of a heat transfer agent such as Watlube Heat Transfer and Release Agent on the new thermostat Slide the new thermostat into the heater block and feed the wires down to TB4 in the Accessory Box Strip the ends of the two new thermostat wires Crimp connectors onto the wires Connect the wires to TB4 terminals 12 and 13 see Figure 40 on page 89 Polarity is not important Replace the Sample System Compartment front panel by completing the steps in the Moving the Front Panel Assembly section on page 89 in reverse order Install the Sample System Compartment cover by completing the steps in the Removing the Cover section on page 78 in reverse order and reconnect the main power to the unit This completes the replacement of the thermostat 98 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 FTC Board The major component associated with the operation of the sensor furnace is the Furnace Temperature Control FTC board which may be located in either the Main Analyzer Unit Accessory Box or a Remote FTC Box Note Some older units also have a transformer to supply the 80 VAC required by previous FTC board designs See Appendix F Previous Configurations for additional informa
60. Cover section on page 78 in reverse order and close the Accessory Box cover 12 Calibrate the new combustibles detector as described in Chapter 4 Calibration This completes the replacement of the combustibles detector Active Element Serial Number SF Label S i Reference Element Retaining Nut Leads Housing Figure 38 Combustibles Detector Orientation 86 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 5 Replacing the Temperature Sensor The temperature sensor maintains the sensor furnace at a constant temperature Either a resistance temperature detector RID or a type K thermocouple TC as specified at the time of purchase may be used for this purpose The temperature sensor is mounted on the top of the sensor furnace and extends approximately 2 into the sensor furnace The temperature sensor is fragile and easily damaged and therefore it must be handled with great care CAUTION Toreplace the temperature sensor the power to the FGA 300H X must be disconnected Therefore replace the temperature sensor and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT These symbols indicate Caution dangerousl
61. EATER BLOCK TEMP ADJ CW TO INCREASE OXYGEN TEMPERATURE ID FUSE 5x20mm T2 5A Front Panel Assembly 12 NEUTRAL EARTH 11 LIVE PHASE Figure 45 Local FTC Fuse and FTC Board Locations Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 2 Replacing a Local FTC Board The Furnace Temperature Control FTC board for local wiring is located behind the front panel in the Accessory Box see Figure 45 The FTC board is a 3 5 x 4 7 in 90 x 120 mm rectangular printed circuit board that maintains a steady sensor furnace temperature in order to ensure accurate operation of the oxygen sensor CAUTION To replace the FTC board the power to the FGA 300H X must be disconnected Therefore replace the FTC board and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT This symbol indicates Caution risk of electric shock GS The only tool needed to replace the FTC board is a screwdriver Refer to Figure 45 on page 100 and complete the following steps to replace the FTC board 1 Open the hinged cover on the standard Accessory Box 2 Disconnect the main power to the unit by removing three wires from TB3 pins 11 12 and Earth 3 Remove the four screws which support the front panel 4 Rotate the Front Panel Ass
62. FGA 300H X Horizontal Gas Analyzer User s Manual 95 Chapter 6 Parts Replacement 6 2 8a Removing the Old Cartridge Heater 1 2 3 4 Disconnect the main power to the FGA 300H X Remove the Sample System Compartment cover as described in the Removing the Cover section on page 78 Access terminal block TB4 by Moving the Front Panel Assembly on page 89 Locate the cartridge heaters in the heater block near the bottom of the Sample System Compartment see Figure 44 on page 95 The cartridge heater wires come out the bottom of the heater block Trace the two wires from the cartridge heater being replaced 75W or 150W to pins 11 and 13 or 12 and 13 on terminal block TB4 in the Accessory Box see Figure 40 on page 89 Disconnect the two wires which correspond to the heater being replaced 75W or 150W Be sure to disconnect ONLY the cartridge heater wires at pins 11 and 13 or 12 and 13 on terminal block TB4 IMPORTANT Do not disconnect any of the other leads at these terminals 7 96 Push on the cartridge heater to be replaced from the bottom end with wires while pulling the same cartridge heater out the top side of the heater block Feed the cartridge heater wires up through the hole from the Accessory Box into the Sample System Compartment and through the heater block Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 86 Installing the New Cartridge Heater 1 Br
63. FH IMPORTANT For compliance with the European Union s Low Voltage Directive 73 23 EEC the standard 300H requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit Because the sensor furnace power feed in the remote FTC Box must also be interrupted a 4 pole disconnect device is required This does not apply to the flameproof 300HX 3 4 Taking Measurements Allow the FGA 300H X to warm up sufficiently before taking any measurements Readings are outputted to the Display Console in percent oxygen or other ordered parameter and or ppmy combustibles Other parameters can be displayed using the keypad If the Display Console is not included in the system use the graph in Appendix C The Nernst Equation to convert the analog output reading into percent oxygen For a more precise mV to oxygen conversion use the following formula 8 20 9 Eo 09V 98 273 bez O2 in Sample as i Note See Appendix C The Nernst Equation for more details on how to perform similar calculations at other operating temperatures Although percent oxygen can still be measured without the Display Console the measurement of combustibles can NOT be accomplished without the Display Console 40 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 3 Operation 3 5 Using the Display and Keypad
64. FTC board When the FGA 300H X detects this error e alarms are activated analog outputs indicate a lack of oxygen on all ranges e the stoichiometric interlock is activated which produces a 1 0 reading on the combustibles display To correct this error refer to the flow diagram in Figure 28 on page 56 and perform the following checks in the order given 5 2 1a Check the Wiring The most common reason for the open circuit error is incorrect or loose wiring Complete the two checks listed below to correct any wiring problems WARNING Be careful when tightening the terminal block electrical connections Full line voltage is present on some terminals in the Main Analyzer Unit the FTC Box and the Display Console IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively A A Model FGA 300H X Horizontal Gas Analyzer User s Manual 55 Chapter 5 Troubleshooting 5 2 1a Check the Wiring cont BLINKING open circuit error E1 Check TB Wiring Check Sensor Wiring Check TC Temp Good Temp Low No Reading Check O2 Sensor Check Furnace Replace RTD TC OL Reading Replace O2 Sensor Good OL Reading Check FTC VAC Out Check Furnace Wiring OL Reading Replace Furnace Line Voltage No Voltage Defective Display Unit Check FTC VAC In Line Voltage No Voltage Teck FIC Fi Fuse Good Replace FTC Board Figure 28 Blinking Flow Diagr
65. GA 300H X Horizontal Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions seuoul s1e1euut IUJ Ul BJO SUOISUBLUIG paljddns p109 eur ajqoyooieq W9 T ql 2 Du ze 1UBlam MalA LNO amp S I 81 S97 o d v 2o J z jeuy seo an 4 00 seueg s zo ZH 09 5 5 E Tal eal s9 1 repe v jy 2 v ds es a 80D 20 8WOD SLNdNI SLAdGLNO Tal eal MalA 3015 gt 69 TT 62 61 S287 MalA avy V6 22 RAR ARBRE A 18 TT 00g AM Jo S UIOW 331 Rack Mount Figure 55 300D Display 131 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions S9YOU s191euui iu ur BJD suorsueuuiq peijddns p109 aun ejqpu201eq W9 T ql S S 64 ez iui r 6S0 ST MIIA LNOSJ
66. GA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 3 Installation Site Install the Main Analyzer Unit in the furnace or boiler wall or in the side of a horizontal or vertical flue duct 2 3 1 Selecting the Site Ideally the probe and probe sleeve should extend approximately 1 ft 30 5 cm into the flue Also the flue gas flow direction should be perpendicular to the probe sleeve or at worst angled away from the open end of the probe sleeve see Figure 12 on page 14 Note Never allow the flue gas flow to be angled directly into the open end of the probe sleeve e Furnaces Locate the analyzer close to the combustion zone typically within the radiant section and always before the convection section Because of the high temperatures in such a location probe material selection should be a primary concern Note If the ambient temperature near the probe can exceed 950 C 1750 F a high temperature probe assembly is required e Boilers The analyzer is best located downstream of the main heater and just before the economizer air heater if there is one The analyzer should not be placed downstream of any air heater because of possible air leaks which will cause inaccurate readings In general the sample point should be an area of high turbulence which will ensure a good homogeneous mixture of the flue gases Conditions to be avoided would include air leaks upstream of the sample point and dead spaces in
67. GA 300H X Horizontal Gas Analyzer User s Manual 79 Chapter 6 Parts Replacement 6 2 2 Replacing the Oxygen Sensor Clips cont 1 2 3 4 12 Remove the Sample System Compartment cover as described in the Removing the Cover section on page 78 Open the Accessory Box and disconnect the oxygen sensor leads from pins 1 and 2 of terminal block TB1 Locate the oxygen sensor and the oxygen sensor clips see Figure 35 on page 79 Use pliers to remove the inner and outer clips from the oxygen sensor To remove the inner clip pinch the ends together and pull the clip out of the oxygen sensor The outer clip is easily removed by pulling it away from the oxygen sensor body Making sure you do not cut off too much of the wire cut off the old inner clip The remaining wire should be left as long as possible Strip 13mm 1 2 of insulation off the inner clip wire Slide the new inner clip over the stripped wire Using a crimping tool crimp the new inner clip onto the inner clip wire Repeat steps 4 through 7 to install the new outer clip Reinstall both clips onto the oxygen sensor Reconnect the oxygen sensor leads to pins 1 and 2 of terminal block TB1 in the Accessory Box Install the Sample System Compartment cover by completing the steps in the Removing the Cover section on page 78 in reverse order and close the Accessory Box cover Recalibrate the oxygen sensor as described in Chapter 4 Calibration This
68. GE Measurement amp Control Solutions Gas Analysis FGA 300H X Horizontal Flue Gas Analyzer User s Manual a k 910 078 Rev E Imagination at wor August 2011 FGA 300H X Horizontal Flue Gas Analyzer User s Manual 910 078 Rev E January 2011 WWW ge mcs com 2011 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this page Preface Information Paragraphs Note paragraphs provide information that provides a deeper understanding of the situation but is not essential to the proper completion of the instructions Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance Caution paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to property or equipment e Warning paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to personnel Cautionary information is also included when applicable Safety Issues WARNING Itis the responsibility of the user to make sure all local county state and national codes regulations rules and laws related to safety and safe operating conditions are met for each installation Auxiliary Equipment Local Safety Standards The user must make s
69. H X Horizontal Gas Analyzer User s Manual Index 163 Index no content intended for this page 164 Model FGA 300H X Horizontal Gas Analyzer User s Manual Warranty Warranty Each instrument manufactured by GE Sensing is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument at the sole discretion of GE Sensing Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Sensing determines that the equipment was defective the warranty period is one year from delivery for electronic or mechanical failures one year from delivery for sensor shelf life If GE Sensing determines that the equipment was damaged by misuse improper installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Sensing the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied including warranties or merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade Return Policy If a GE Sensing instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Sensin
70. JD suoisuauJic WWO2D Sau ap ST 8 r 60 22 IT Wu Ap A 1 MA WOLLOS 2 OS MAIA 3GIS 7 981 m S S OUT MalA LNO33 po J8 02 _ aAOWAI 0 jouondo pt p nb 6umi eqni wwgg sdUDIDAa D Ma3lA YVI8Y L 31 puondo 7 T Es Dumu aqn wwgg Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions Jou JoyoIdsy h a Y KEE LOH AH3A JUV S3OW4UNS ONINUVM 00 Solas se Y 26 e gt m 56 Ce 39 U UO O1Q 05 66 0S2 99UDJD9JD 9T Ot Aug epis siu M S Hulydo g 1940947 a6up j _ Standard Weatherproof pnoJus m 6 9 OST US v 0l 792 Ult T JO ug T ug o 7 suondo yybua A Y BQO Figure 50 Main Analyzer Unit e2uDJDe 6 T gro 126 Appendix B Outline and Mounting Dimensions pnoJus NIA 3015 Ult T JO ut ulgo 3 ld leen 31qp M S Bury207 suondo Dua awa Y 9gqoJg 7 2 OF pajpas 10120J x s9 1 opp 6 S OST puno
71. Model FGA 300H X Horizontal Gas Analyzer User s Manual 158 Appendix F Previous Configurations al cal dW3l 3SVIYINI OL MO 1SAFQV dell TZ2T 20LT 213 Qu v2 U3TIOSINOD delt SJOVNYNS tal OIN XO tO ID PO OC e S831V3H IVISOW83H1 A in 21 Q 1y JOVNYNS DOM XO LO xf PO ON e JALOV OV 00 M W LO xf PO NI e 338 e a e a YOSNAS N39AXO YOSNAS J8N1VIIAWIL 0193130 SATAILSNEWOD LINA AV del IWLISIG XO8 213 SLOWSY LINA YIZATVNV NIVIA v F 517 Re f dwg 1442 Previous re Figure 69 Wiring Diagram 159 Model FGA 300H X Horizontal Gas Analyzer User s Manual no content intended for this page 160 Model FGA 300H X Horizontal Gas Analyzer User s Manual A Accessory BOX ess vowed loa isk Ga EV PAR 6 13 Alarms Selecting Combustibles Trigger Mode 36 Selecting Oxygen Trigger Mode 36 Setting Combustibles Trip Point
72. OPS AAA AAA ARANA AA A as 55 Eet ste E 55 5 2 2 PPRPP and Normal ele Wee dd a on ai ots 65 A REAGAN DEE 65 5 2 4 Oxygen Concentration Reads Constant 20 9 ce pot chee Ve e b e OR Oc RS 67 5 2 5 OnVvoem Redding Ab ve 20 9 cutie A E ecw b aE 69 5 26 DR gemRegading TOO Dosis Credo ALPE CE HR C a D ORCI E eb EAR 69 52 Oxygen Redding TOO IA as 70 Combustibles EOFS oves se soo t t Et eee teles Aa 71 5 511 O Out Ol Range INdICATO c uvis vate RO NEN VON RICE AS UP RUF FREE a RO HE SIN 71 5 52 0123580 Negative ROCCO ative Geist en Cees esu cU une ce LM NE Du eds NI DOM S 72 5 3 3 1 0 Negative Out Of Range INdiCator e E een n RENE 73 5 3 4 Low Combustibles Reading but Correct Oxygen Reading ce cece eect eee e rro 74 Calibration BEE 75 AR lee RE 75 O AONA ee EE 75 54 Seda Space Proble EE 75 vi Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 1 6 2 6 3 6 4 6 5 E A COENEN Main Analyzer a ona 6 2 Removing the CO dd oia 6 2 2 Replacing the Oxygen Sensor Cps 0 0 cece ccc eee eee ee eee 6 2 3 Replacing the Oxygen Sensor sue ica a sews a 6 2 4 Replacing the Combustibles Detector o oooooocoooooooooo 6 2 5 Replacing the Temperature Sensor 6 2 6 Moving the Front Panel Assembly 0 00 c cece cence ees 6 2 7 Replacing the Sensor Furnace 6 cece cece cence es 6 2 8 Replacing the Cartridge Heaters 0 ccc eee cece eee ees 6 2 9 Replacing t
73. Oxygen and Combustibles Channel 1193 504 5 Fuse 200mA 1193 503 5 Fuse 100mA for 220VAC units 106 Model FGA 300H X Horizontal Gas Analyzer User s Manual 6 5 Spare Parts cont Part Number 1214 511 Chapter 6 Parts Replacement Table 21 Spare Parts List FGA 300H X Description Inner Oxygen Sensor Clip 1214 510 Outer Oxygen Sensor Clip 1705 533 Combustibles Detector Assembly 1705 534 RTD Assembly 1190 505 01 Thermostat and Leads 1227 502 01 Cartridge Heater 150W 115VAC 1227 502 02 Cartridge Heater 150W 220VAC 1227 505 01 Cartridge Heater 75W 115VAC 1227 505 02 Cartridge Heater 75W 220VAC 1420 520 01 Heater Block 300H 300V 1420 520 02 Heater Block 300HX 300V 1410 502 Gasket Hi Temp 1705 546 Thermocouple K Type Temperature Detector Assembly 1193 501 Fuse 2 5A 1705 526 01 Oxygen Sensor Assembly Std Gases 1705 526 02 Oxygen Sensor Assembly Stoichiometric Combustion CO 1703 1271 02 Temperature Control Board 115VAC K Type Thermocouple input 1703 1271 03 Temperature Control Board 220VAC K Type Thermocouple input 1703 1271 04 Temperature Control Board 115VAC RTD input 1703 1271 05 Temperature Control Board 220VAC RTD input 1705 552 02 Furnace Assembly with bracket 1705 549 01 Cal Port Flowmeter 300H 1705 549 02 Cal Port
74. Re Ki e 9BUD y Quan eBund mp 9 DA J9YIDAJB IV130 NOLLV1N3140 39NV 13 Aale Dun Malas Bulyo07 ale T XO8 AYOSSIDOV MalA dOL J3ZAIVNV V V NOIL93S f E O E 2 5141 ql 64 64 9 1yBiam JOUIWON SZ Seuoul s191euut jiuu Ul aso suoisueuuiq JDUIWON 2 S2 pl papas A puuJOu Eyo 9 S09 UOnDJqi D2 nid puo do E uurener 1e u 403Duidsy uado s D D UILU 99G2 ie u aBund JIV Buiqny 7 T 40 99 Sj9 ut Iv 079 712 09 Proof Flameproof Explosion Figure 51 Main Analyzer Unit 1 of 2 127 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions SECTION A A INTERNAL CALIBRATION PIPE D 2 E E u O 2 O a Uu
75. S UE Eege toto ou t lll eii 145 Appendix F Previous Configurations E i s rrr 147 F 2 Testing the FTC Board and Transformer e cce estt op rd ecce Tob atra e oc t due Acid 148 F3 Replacing the FIC Boda RUSO caida bid 150 Pa MReplacingdhie FTO BOA d iue oer late erre CECI TA Lie tro EC bees Sd elo S Oe plas go pde 151 Rb Replacing Local TEGIPISPOEIIGE s eum uio ri Fou IA Ore boreal Ot AA 152 F 6 Replacing a Remote Transformer S se ca ted ite p Erb EUER A dM RE Gr ka A ae REA 154 El Adjusting the Sensor Furnace Temperattires e E CIS 155 F 8 Previous Wiring Diagrams and Circuit BOOKS one Cet ee ote A SO ELS 155 viii Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 1 General Information Chapter 1 General Information 1 1 Overview Process plant managers are usually looking for ways to reduce expense and increase profitability When combustibles are burned as part of the operation and that combustion is incomplete allowing unburned fuel to escape costs go up and profits go down A reliable system for analyzing flue gas can provide the necessary information to adjust the flow of oxygen increase the efficiency of the combustion and result in huge cost savings for the overall operation To meet these specific needs GE provides the FGA 300H X Horizontal Flue Gas Analyzer which monitors the efficiency of a furnace or boiler by measuring excess oxygen and or ppm unburned combustibles in the flue gases To
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77. Sensor too cold high sample pressure Possible Combustibles Error Indicators combustibles level is greater than 1 0 Out Of Range Indicator alarms activated 20 000 ppmy 1 combustibles channel is out of 12340 Negative Reading no response calibration 2 wiring of element reversed 1 reference element open or active 1 0 Negative element shorted Out Of Range no response combustibles channel severely out of Indicator calibration detector incorrectly wired detector physically damaged or but Correct Oxygen Reading a i detector aging calibration flow too low a 1 0 error indicator also appears on the combustibles display see first O error 54 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 Oxygen Errors This section discusses each of the possible oxygen errors listed in Table 11 on page 54 If an error other than those listed should occur contact the factory for assistance 5 2 1 Blinking An oxygen display that alternates between a blank screen and a reading indicates an open circuit error and can be caused by one of the following conditions Note Before proceeding make sure the unit is not still warming up This condition may also be indicated by an E1 error code faulty wiring faulty oxygen sensor e faulty RTD TC temperature sensor e faulty sensor furnace e faulty furnace temperature control
78. T OD uonpo 99 SNJD oddy N MODUIM 27 OTTO Jop uonpoynJe eJnso pu3 y Vo SOZT t7 _ Y E 1 8 8 1 5917 aaa sayoul sJe3euupiuu ut 81D SUOISUSWIG Bunoy S9dl 104 Buly O 114 IO 9 S0T 5 Ap 3ubieM 70 OT SS ed Bench Mount Figure 59 300D Display 135 Model FGA 300H X Horizontal Gas Analyzer User s Manual no content intended for this page 136 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix C The Nernst Equation Appendix C The Nernst Equation C 1 Overview The FGA 300H X uses the Nernst Equation to calculate the oxygen content of the flue gas When a Yttrium doped zirconium oxide ceramic is heated to a temperature above 650 C it becomes an electrolytic conductor as vacancies in the crystal lattice permit oxygen ions to diffuse into the ceramic If there are different oxygen partial pressures on the two sides of the ceramic cell oxygen ions will migrate along the resulting concentration gradient This constitutes a transfer of electrons from one face of the ceramic to the other If the transferred charge is allowed to accumulate it gives rise to a potential gradient acting in the opposite direction thus tending to oppose further diffusion C 2 Equilibrium Conditions Under equilibrium conditions the potential gradient exactly ba
79. TC board fuse and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT This symbol indicates Caution risk of electric shock AN The only tool needed to replace the remote FTC board fuse is a small screwdriver Refer to Figure 46 on page 104 and complete the following steps to replace the FTC board fuse 1 Disconnect the main power to the FGA 300H X 2 Open the hinged cover on the standard weatherproof FTC box For an explosion proof flameproof FTC box loosen the locking set screw on top of the FTC box and using a long screwdriver across the slots provided unscrew the cover from the enclosure 3 Locate the fuseholder on the FTC board Using a small screwdriver remove the spring loaded cover from the fuseholder and discard the old fuse 4 Install a new fuse of the same type and size see the label near the fuseholder or Chapter 7 Specifications and reinstall the fuseholder cover 5 Close the cover on the remote FTC Box and reconnect the main power to the system The system may now be placed back into service 102 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 4 Replacing a Remote FTC Board The Furnace Temperature Control FTC board for remote wiring is located in a Remote FTC box The FTC board is a 3 5 x 4 7 in 90 x 120 mm rectangular printed circuit board that maintains a steady sensor furnac
80. W 038 1038 HOLIMS LOSNNODSIC SNIVIA XHOO LON AINO HOOS 3 LON Appendix D Wiring Diagrams and Circuit Boards V ldSIQ 1ndinO T Z8l N39AXO eal ON T 81 GIEL ON EIER WNIvIV N39AXO lddfls SNIVW j3ZA IVNV DST ON 3AN 831V3H VIN 93503 3AN SDVNYNS YSTIONLNOD 39VN8N3 T 2a1 23 YOSNAS NIDAXO 2 291 93 INdLNO 28l agwod v c8l ON v 8l Qo G F al ON 98l SLAdLNO WNIvIV anos HO LV STVNIWS3L GOO day SIYLNID UJU109X09 S3IH LN3 LdN DIE XZ S9d S 91 911 p X33 NMOHS LON 0002 dX3 S TalL YOSNAS JYNLVYAdWISL 338 9 Tal NOWWOD Tal SLAdNI SI41N39 WUIZ9 S3IH LN3 WWOZ X17 99dl Goose diM JALOV S38 1N32 Uul0SXx8g S3IH LN3 Ule xe Sdl HOO VOI Sauee sezhjeuy seg ang 30193130 SFISILSNEWOD SI41N39 WUGS S3IH LN3 LAN t7 XE S9dl S SL 911 P X33 XHOOE VOI Ee isplay Enclosure inD ith FTC Board ion Diagram w Interconnect igure 63 F Model FGA 300H X Horizontal Gas Analyzer User s Manual 144 Appendix E Default Settings Appendix E Default Settings E 1 Overview For CE Mark compliance th
81. a Local Transformer cont Remove the FTC mounting plate by removing the four screws on the right and left side of the plate Remove the four hex nuts and washers from the old transformer Move the old transformer aside do not disconnect any wires yet and place the new transformer into the accessory box Disconnect the leads from the old transformer one at a time and connect the corresponding lead from the new transformer in its place until all of the new leads have been connected Verify that the new transformer leads are properly connected by referring to Figure 68 on page 158 Remove and discard the old transformer in accordance with local regulations Secure the new transformer in place with the four hex nuts and washers that were previously removed Reinstall the FTC mounting plate Reinstall the FTC board Reconnect the 12 pin connector to the FTC board Reconnect the main power to the system Using a digital multimeter measure the sensor furnace voltage across pins 5 and 6 of terminal block TB1 in the Accessory Box NOT on the FTC board H the measured voltage is approximately 80 VAC the new transformer is working properly Close the cover on the Accessory Box This completes the replacement of the transformer Model FGA 300H X Horizontal Gas Analyzer User s Manual 153 Appendix F Previous Configurations F 6 Replacing a Remote Transformer In a remote FTC setup the sensor furnace power transformer is located near
82. ad sealant gives off combustible vapors that can cause reading errors 2 Do not handle the oxygen sensor or combustibles detector with bare hands Although some scratches on the platinum coating can be tolerated rubbing the coating should be avoided 3 Scrubbing an oxygen sensor or washing a hot sensor in cold water can damage or destroy it Clean a sensor only by rinsing it with clean water after the sensor has cooled 4 Installing a cold probe and or probe sleeve into a hot manifold can cause these components to seize in the manifold All fittings should be cool when installing them into the unit Model FGA 300H X Horizontal Gas Analyzer User s Manual 39 Chapter 3 Operation 3 3 Powering Up the System After checking the wiring connections apply power to the analyzer The FGA 300H X does not have its own ON OFF switch Thus power is applied to the unit as soon as the external disconnect device is energized Allow the analyzer to warm up for at least one hour three hours if possible before taking measurements WARNING To prevent corrosion the analyzer must be powered up immediately after installation If the analyzer is left installed without power the unit s components become susceptible to acid condensation that will cause corrosion If the power must be removed for more than thirty minutes purge the analyzer through the calibration port with a continuous flow of instrument air at a minimum rate of 150 cc min 0 3 SC
83. aising the temperature of the active element above that of the reference element See Figure 7 Flue Gas Flow BEEN _ Element Inert Coating Active Element Platinum Catalyst Combustibles Sensor Figure 7 Combustibles Detector Elements The resulting temperature differential between the active and reference elements is proportional to the concentration of combustibles in the sample and a corresponding resistance change is then converted into a reading of parts per million by volume ppmy of combustibles 8 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation Chapter 2 Installation 2 1 Overview This chapter provides a general description of the standard weatherproof FGA 300H and explosion proof flameproof FGA 300HX and gives directions on how to install wire and set up each model for operation Note If more than one analyzer system is being installed be aware that each system is a matched set i e each Remote FTC Box probe probe sleeve and Display Console must be matched to a specific analyzer Refer to tags on the box probes sleeves displays and analyzers in order to match the units correctly IMPORTANT For compliance with the European Union s Low Voltage Directive 73 23 EEC the standard 300H requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and loca
84. ake 45 60 seconds to fully insert the 6 sensor into the furnace If the sensor is inserted too quickly it will crack After positioning the titanium washer against the fitting nut finger tighten the oxygen sensor into its fitting on the bottom of the sensor furnace IMPORTANT Jf the sensor furnace is hot allow the oxygen sensor to stand for at least two minutes before proceeding 7 Turn the fitting nut clockwise as viewed from below the oxygen sensor to securely tighten the oxygen sensor Use a torque wrench set at 56 N m 480 in Ib for this purpose IMPORTANT Jf the sensor furnace is hot set the torque wrench at 70 N m 600 in Ib 8 9 10 Reinstall the inner and outer clips onto the oxygen sensor body Install the Sample System Compartment cover by completing the steps in the Removing the Cover section on page 78 in reverse order Calibrate the new oxygen sensor as described in Chapter 4 Calibration This completes the replacement of the oxygen sensor Model FGA 300H X Horizontal Gas Analyzer User s Manual 83 Chapter 6 Parts Replacement 6 2 4 Replacing the Combustibles Detector The combustibles detector is located on the side of the manifold below the sensor furnace The combustibles detector easily unscrews from the manifold and slips out of its housing CAUTION The combustibles detector is very fragile Handle it with great care An open end wrench and a torque wrench are the only too
85. alyzer Model FGA 300H X Horizontal Gas Analyzer User s Manual 115 Chapter 7 Specifications 7 5 Ordering Information cont The information below shows how the FGA 300 Probe and Probe Sleeve Part Number is configured from the options specified FGAPS Table 26 FGA Probe and Probe Sleeve Ordering Information CATEGORY OPTIONS 1 below 650 C Temperature 2 650 to 950 C Range 3 950 to 1600 C 4 above 1600 C 1 Standard sampling method Sampling 3 Aspirated sampling method Method S Special sampling method 1 0 6m long Nominal 2 1 0m long Length 4 1 4m long see note S Special Note The 1 4m length is normally only available for temperatures over 950 C where B 3 or 4 Note f the unit has an aspirator choose Sampling Method option C 3 Aspirated 116 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix A Rotary Switch Settings Appendix A Rotary Switch Settings A 1 Overview The Display Electronics Console for the FGA 300H X analyzer is completely configured at the factory to meet the specified requirements However the instructions in this appendix may be used to complete the following adjustments e Selecting the Fuel Type e Selecting the Display Parameter e Adjusting the Oxygen Channel e Adjusting the Combustibles Channel CAUTION The display circuitry is factory set and should only be adjust
86. am 1 Check all wiring including the factory wiring on the terminal blocks in the Main Analyzer Unit remote FTC Box and Display Console Refer to the wiring instructions in Chapter 2 Installation to make sure that all wires are attached to the correct pins If any connections are loose turn the screws clockwise with a small screwdriver to secure the connections 2 Locate the oxygen sensor clips see Figure 29 on page 57 which shows the sample system with the analyzer enclosure removed and short them together with a jumper The oxygen display should read 20 90 or 0 mV by pressing the mV key If the wiring is good and a 20 9096 oxygen reading is obtained with the shorted clips remove the jumper and proceed to the sensor furnace temperature check Note Ifan open loop OL is measured at the oxygen sensor clips recheck the wiring and try again If the OL reading repeats contact the factory for assistance 56 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 1a Check the Wiring cont Outer Clip Inner Clip Figure 29 Oxygen Sensor Clips 5 2 16 Check the Temperature Sensor If the FGA 300H X is fitted with an RTD temperature sensor complete Step 1 If the FGA 300H X is fitted with an optional thermocouple TC temperature sensor skip to S
87. and the corresponding potential calibration errors shown in Table 10 are introduced Table 10 Calibration Uncertainty Error As shown in Table 10 a calibration uncertainty of about 3 5 is introduced by the calibration gas uncertainty alone 44 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 4 Calibration 4 5 Calibrating the Oxygen Sensor To calibrate the oxygen sensor introduce the chosen calibration gas through the sample system However because the sensors can be cooled by a high flow rate the flow rate of the calibration gas must be regulated After the calibration gas flow rate is adjusted to the proper value a calibration check can be performed 4 3 1 Regulating the Calibration Gas Flow A temporary connection is usually made for calibration A blank plug is supplied with the FGA 300H X to seal the calibration gas inlet when not in use However if a permanent connection is preferred it should be as short as possible with an isolation valve right at the calibration gas inlet on the analyzer Each analyzer is tagged with its optimum calibration gas flow rate based on the analyzer and sampling probe sleeve combination Typically this value will be 220 240 cc min 0 4 0 5 SCFH To set up for calibration complete the following steps 1 Remove the blank plug from the calibration gas inlet port Refer to Figure 25 on page 46 for the location of the calibration inlet port on the Ma
88. ange made to R4 Therefore make the adjustments in small increments and allow several minutes for each new reading to stabilize IMPORTANT According to the Nernst equation a 5 error in the mV output reading from the oxygen sensor would require a temperature adjustment of approximately 50 C As the FTC setting is unlikely to be the source of such a large error if the measurement error is greater than 5 of the reading contact the factory for assistance in tracing the source of the problem Model FGA 300H X Horizontal Gas Analyzer User s Manual 49 Chapter 4 Calibration 4 4 Calibrating the Combustibles Detector In order to properly calibrate the combustibles detector the following three steps must be performed check the operating temperature of the combustibles detector e perform a zero check e perform a span check 4 4 1 Checking the Operating Temperature Before beginning the calibration the operating temperature of the combustibles detector should be checked The operating temperature of the combustibles detector is controlled by the cartridge heaters in the heater block The heaters maintain the combustibles detector at a steady temperature to ensure consistent measurements Do not proceed with the calibration if the operating temperature is incorrect At the normal operating temperature of 225 C 437 F the resistance of the combustibles detector s active and reference elements should measure between 1800 and 1900 ohms
89. ange mounting holes to coincide with the holes in the existing mating flange see Figure 14 on page 18 2 Thread the probe and then the probe sleeve into the manifold assembly located in the rear of the analyzer When properly installed the probe sleeve should extend approximately 3 mm 12 in beyond the end of the probe CAUTION Do not install a cold probe and or sleeve into a hot manifold as the threads will expand and seize upon warming If such a situation is unavoidable thread the components loosely into the manifold and allow to warm for a few minutes before fully tightening Note As it is unnecessary to make the sample probe threading leak tight do not use a thread sealant on the threads However a dry high temperature graphite based lubricant may be used 3 Units intended for operation at temperatures below 950 C 1 750 F include a 32mm 1 1 4 in shroud attached to the end of the probe sleeve Secure the shroud to the end of the probe sleeve by tightening the six 6 set screws IMPORTANT Never attempt to install a shroud on a non metallic probe assembly as the probe sleeve will crack CAUTION Ifthe analyzer contains a combustibles detector do not use silicon based sealers or lubricants on any part of the analyzer The presence of silicon in the analyzer will damage the combustibles detector Model FGA 300H X Horizontal Gas Analyzer User s Manual 19 Chapter 2 Installation 2 4 Installing the Probe and Probe
90. ansformer For units so equipped refer to Appendix F Previous Configurations for troubleshooting instructions 64 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 2 PP PP and Normal Reading Alternate This oxygen display condition indicates that the signal from the oxygen sensor has changed less than 0 2 mV in 15 minutes Such a situation can indicate either that the probe is plugged or that the process is unusually stable When this error condition occurs the alarm relay is activated the analog outputs are not affected Plugging of the probe usually occurs in very dirty applications If the problem is a plugged probe use a blowback system contact the factory for details to unplug the analyzer If the flue gas composition is really that stable this warning may be ignored 5 2 3 Blinking Reading A blinking reading on the oxygen display is usually caused by either of two conditions the oxygen sensor has exceeded its useful lifetime the sensor furnace is not at the proper temperature To correct this condition refer to the flow diagram in Figure 33 on page 66 and perform the following tests 5 2 3a Check the Oxygen Sensor Every two hours the FGA 300H X automatically measures the impedance of the oxygen sensor If the impedance is above the acceptable range the oxygen display reading blinks This means the oxygen sensor is aging and should be replaced To test the oxygen s
91. by a short in the oxygen sensor wiring a severe air leak in the plumbing or a defective Display Console A brief description of how to remedy this problem is presented below WARNING The main analyzer enclosure is hot Use heat resistant gloves when handling the enclosure IMPORTANT This symbol indicates Caution risk of electric shock AN Refer to Figure 29 on page 57 for the location of the oxygen sensor clips and check for a short circuit in the contact clip wiring two wires touching If this does not correct the problem proceed to the next section 5 2 4a Check the Oxygen Sensor Wiring 5 2 4b Check for Plumbing Leaks A plumbing leak permits cross contamination of the reference air and the flue gas sample Use the following steps to remedy the problem 1 Make sure that the calibration gas port on the Main Analyzer Unit has not been left open This would admit atmospheric air into the sample system and force a 20 9 reading 2 Remove the Sample System Compartment cover and check all sample system plumbing connections for leaks Make sure that the oxygen sensor and combustibles detector ports are properly sealed When the reference air is contaminated by the same gases that are being measured the oxygen sensor generates a 0 00 mV analog output signal and a 20 9 oxygen reading Removing the cover permits uncontaminated reference air to enter the unit If removing the cover and fixing any plumbing leaks does not cause the 20 9
92. completes the replacement of the oxygen sensor clips 80 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 3 Replacing the Oxygen Sensor The oxygen sensor is mounted below the furnace and is readily accessible for quick and easy replacement The following items are needed to replace the oxygen sensor open end wrench torque wrench Molykote High Temperature Non Silicone Lubricant e pliers Note When replacing the oxygen sensor handle the sensor only by the fitting at its base The oxygen sensor can be replaced with the sensor furnace either hot or cool However the procedures are slightly different and particular attention should be paid to the noted variations in the following steps IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively If replacing the oxygen sensor with a hot furnace the power should remain on during the process and the following warning should be observed WARNING There are extremely hot surfaces in the analyzer Touching these surfaces will result in serious burns Use heat resistant gloves while replacing the oxygen sensor 1 Remove the Sample System Compartment cover as described in the Removing the Cover section on page 78 2 Locate the oxygen sensor and the oxygen sensor clips see Figure 35 on page 79 Use pliers to remove the inner and outer clips from the oxygen sensor To remove
93. ded to replace the FTC board is a nutdriver or similar tool Refer to Figure 64 on page 147 for local FTC or to Figure 65 on page 149 for remote FTC and complete the following steps to replace the FTC board 1 Disconnect the main power to the FGA 300H X 2 Open the hinged cover on the standard Accessory Box or on a standard weatherproof remote FTC box For an explosion proof flameproof remote FTC box loosen the locking set screw on top of the FTC box and using a long screwdriver across the slots provided unscrew the cover from the enclosure 3 Remove the connector from the 12 pin terminal block TB1 on the FTC circuit board 4 Remove the four hex nuts and washers located in the corners of the old FTC board and lift the FTC board out of the enclosure Note Install the new FTC board in the same orientation as the old FTC board The line voltage for the new FTC board is factory set based on the unit s serial number 5 Locate the new FTC board over the standoffs in the enclosure Make sure that the new FTC board is in the same orientation as the old board and not rotated by 180 6 Replace the four hex nuts and washers in the corners of the new FTC board and tighten the nuts securely 7 Reconnect the connector to the 12 pin terminal block TB1 on the new FTC circuit board 8 Close reinstall the cover on the FTC Box and reconnect the main power to the system 9 Refer to Chapter 4 Calibration and recalibrate the oxygen sensor
94. djust trimmer potentiometer R105 on the 300D Display printed circuit board This adjustment is not as sensitive as the zero adjustment with R111 and the R105 adjustments may be made in larger increments Refer to Figure 27 on page 51 for the location of R105 and adjust it in the appropriate direction e Turn R105 clockwise to increase the ppmy reading or e Turn R105 counterclockwise to reduce the ppmy reading This completes the calibration of the combustibles detector 52 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting Chapter 5 Troubleshooting 5 1 Overview The FGA 300H X has been designed to overcome most of the problems commonly associated with monitoring flue gases However because of the corrosive and extreme conditions under which the instrument must operate some difficulties may still be encountered The procedures for resolving many of these situations are discussed in this chapter If the information provided in this chapter is not sufficient please consult the factory for assistance The FGA 300H X analyzer has two sets of error indicators that can occur oxygen measurement errors e combustibles measurement errors Each error indicator appears on the corresponding readout of the 300D Display Console Thus if there is an oxygen measurement error the error indicator will appear on the oxygen readout Refer to Table 11 on page 54 to troubleshoot the FGA 300H X analyzer
95. e Then add the values of the column label 200 and the row label 70 together to determine the operating temperature of the sensor furnace 270 0 385 58 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 16 Check the Temperature Sensor cont 2 Locate the Main Analyzer Unit TC leads at pins 3 and 4 of terminal block TB1 in the Remote FTC Box a Using a digital multimeter measure the voltage across the TC terminals One of the conditions listed in Table 14 should occur Table 14 Thermocouple Voltage Readings Voltage Reading Recommended Action 30 32 mV 700 C The temperature is good proceed to the oxygen sensor check less than 29 mV The temperature is low proceed to the sensor furnace check 0 mV The TC is defective and must be replaced see Chapter 6 Parts Replacement b Complete the action recommended in Table 14 Note lfavoltage reading other than those listed above is obtained refer to Figure 30 or Table 15 on page 60 to determine the operating temperature of the sensor furnace A standard FGA 300H X operates at a temperature of 700 C 35 Ww E O gt
96. e cont 3 Reconnect the sensor furnace leads to pins 12 and 14 of terminal block TB3 in the Accessory Box Sensor Furnace Internal Leads ANS s Terminal 4pl To Accessory Box Ceramic Block Figure 31 Bottom View of Furnace Table 17 Sensor Furnace Resistance Readings Resistance Reading Recommended Action There is a bad connection on the ceramic block Make sure the wires are fed all the way through the ceramic block and exit on the opposite side from which they were inserted Tighten all four screws and verify continuity across the ceramic block see Figure 31 Check the wires from the Accessory Box to the ceramic block to see if they are broken or loose If the wiring is good the sensor furnace is defective and must be replaced refer to Chapter 6 Parts Replacement open loop OL 4 Complete the action recommended in Table 17 62 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 21e Check the FTC Board 1 Using a digital multimeter measure the FTC board s AC output voltage to the sensor furnace across pins 12 and 14 on terminal block TB3 in the Remote FTC Box and across pins 3 and 4 of terminal block TB1 on the FTC board See Figure 32 for the terminal block locations and record the two voltage readings LA ES VSET gt EG VTEMP ELARIN T82 1 RTO TC 182 2 RTO TC 182 3 EXT CIC
97. e Display Board Fuse The display board fuse is located on the digital display printed circuit board in the 300D Display Console CAUTION To replace the display board fuse the power to the FGA 300H X must be disconnected Therefore replace the display board fuse and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT This symbol indicates Caution risk of electric shock AN The only tool needed to replace the display board fuse is a screwdriver Refer to Figure 47 and complete the following steps to replace the display board fuse 1 Disconnect the main power to the FGA 300H X 2 Open the hinged cover on the standard Display Console For the panel mount bench mount or rack mount versions the fuseholder is accessible through the back panel 3 Locate the fuseholder on the display board Using a screwdriver remove the spring loaded cover from the fuseholder and discard the old fuse 4 Install a new fuse of the same type and size see the label near the fuseholder or Chapter 7 Specifications and reinstall the fuseholder cover EHE Eau Epp Figure 47 Display Board Fuse 5 Close replace the cover on the Display Co
98. e FGA 300H must meet both the EMC and LVD directives The FGA 300HX must meet only the EMC directive IMPORTANT CE Mark compliance is required only for units used in EEA countries IMPORTANT For EN 61000 4 3 the FGA 300H X meets Performance Criterion A except at a limited number of frequencies Criterion B per EN 61326 E 2 EMC Compliance For EMC compliance the electrical connections must be shielded and grounded as shown in Table 34 After all the necessary electrical connections have been made seal any unused cable entry holes with standard conduit plugs or equivalent Note Jf the instructions in this appendix are followed the unit will comply with the EMC Directive 89 336 EEC Table 34 Wiring Modifications for EMC Compliance Connection Wiring Modification Use shielded cable to connect power to the FGA 300H X Power Select the cable entry closest to the chassis ground Connect the power line ground wire and the shield to the nearest chassis ground terminal Use shielded cable to interconnect the FGA 300H X with any external input output devices Connect the shields to the nearest chassis ground terminal Wires installed in properly grounded metal conduit are not required to have their own shield E 3 LVD Compliance Input Output For compliance with the European Union s Low Voltage Directive 73 23 EEC the analyzer requires an external power disconnect device such as a switch or circuit brea
99. e and discard the old transformer in accordance with local regulations Secure the new transformer in place with the four hex nuts and washers that were previously removed Sm SEI o SS Reconnect the main power to the system 10 Using a digital multimeter measure the sensor furnace voltage across pins 5 and 6 of terminal block TB1 in the remote FTC Box NOT on the FTC board If the measured voltage is approximately 80 VAC the new transformer is working properly 11 Close reinstall the cover on the remote FTC Box This completes the replacement of the transformer 154 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix F Previous Configurations F 7 Adjusting the Sensor Furnace Temperature In Chapter 4 Calibration instructions are given for adjusting the operating temperature of the sensor furnace via a potentiometer on the FTC circuit board For units fitted with the previous version of the FTC circuit board 1703 92 this potentiometer is designated as R28 and is located as shown in Figure 64 on page 147 or in Figure 65 on page 149 The calibration instructions are otherwise identical F 8 Previous Wiring Diagrams and Circuit Boards The following drawings are included for reference to previous versions of the FGA 300H X They include e FTC Circuit Board layout Display Circuit Board layout Wiring Diagram with transformer Wiring Diagram without transformer Model FGA 300H X Horizontal Gas Analyz
100. e flue gas can not generate an explosive atmosphere After removing power wait 5 minutes before opening European Compliance The unit complies with EMC Directive 2004 108 EC and the 2006 95 EC Low Voltage Directive Installation Category II Pollution Degree 2 For EN 61000 4 3 the FGA 300H X meets Performance Criterion A except at a limited number of frequencies Criterion B per EN 61326 Model FGA 300H X Horizontal Gas Analyzer User s Manual 109 Chapter 7 Specifications 7 2 Oxygen Specifications Sensor Stabilized zirconium oxide zirconia ceramic Accuracy Logarithmic Output 1 of reading Linear Output 1 of full scale Repeatability Logarithmic Output 0 29 of reading Linear Output 0 5 of full scale Drift Less than 0 1 of sensor output per month Sample Temperature 950 C 1 742 F maximum higher sample temperature version available Calibration Through calibration port using a certified mixture of O in N5 7 3 Combustibles Specifications Detector Catalytic combustion platinum resistance thermometer Accuracy 5 of reading Repeatability 1 of full scale Drift Less than 2 of full scale per month Sample Dew Point 180 C 356 F maximum higher dew point version available Calibration Through calibration port using a certified mixture of CO and H in N with O5 110 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 7 Specifications 7 4
101. e flue gas concentrations accurately This indicates that proper operating conditions have been achieved and the analyzer can be expected to perform reliably 5 42 Forced Flow Problem If a flow rate higher than the tagged calibration gas flow rate is required to calibrate the analyzer either the flue gas velocity is too high or the probe is not perpendicular to the flue gas flow direction Under such conditions the sample is not entering the probe by diffusion only but it is being forced into the probe instead In addition to the calibration problem sensor detector life may be shortened and analyzer plugging may occur If forced flow is confirmed as the problem refer to Chapter 2 Installation for instructions on proper orientation of the analyzer 5 4 3 Dead Space Problem The analyzer was successfully calibrated at the tagged calibration gas flow rate and the analyzer responded quickly to the calibration gas However there is a significant delay in reading the correct flue gas concentrations after turning off the calibration gas When this problem occurs it is very likely that the probe tip is located in a dead space After the analyzer is correctly reading the flue gas concentration switch on the calibration gas just long enough to get the correct reading As soon as the analyzer reads the correct value quickly shut off the calibration gas One of two responses should occur 1 Ifthe recovery time is still too long plugging may be
102. e temperature in order to ensure accurate operation of the oxygen sensor CAUTION To replace the FTC board the power to the 300H X FGA must be disconnected Therefore replace the FTC board and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT This symbol indicates Caution risk of electric shock AN The only tool needed to replace the remote FTC board is a screwdriver or similar tool Refer to Figure 46 on page 104 and complete the following steps to replace the FTC board 1 Disconnect the main power to the FGA 300H X 2 Open the hinged cover on the standard weatherproof FTC box For an explosion proof flameproof FTC box loosen the locking set screw on top of the FTC box and using a long screwdriver across the slots provided unscrew the cover from the enclosure 3 Remove the connectors from the 5 pin terminal block TB1 and the 8 pin terminal block TB2 on the FTC board 4 Remove the four screws located in the corners of the old FTC board and lift the FTC board out of the enclosure Note Install the new board in the same orientation as the old board The line voltage and temperature sensor type for the new FTC board are factory set based on the unit s serial number 5 Locate the new FTC board over the standoffs in the enclosure Make sure that the new FTC board is in the same orientation as the old board and not rotated by 180 6 Replace t
103. ecting from the manifold assembly at the back of the analyzer see Figure 13 On the explosion proof flameproof 300HX the pipe is 2 NPTM Use this pipe to attach a user supplied flange or fixing plate or to install the analyzer using one of the flanges available from the factory Note On request the factory can supply the analyzer as a flange mounted unit Standard available options are 3 300 Ib ANSI 4 150 lb ANSI and DN80 PNI flanges Sample System Compartment Threaded Pipe Mounting Flanges Short Pipe Metal Wall gt Cover Blocking Screw Probe Sleeve _ IN s this side only Gasket Hardware Accessory Box Figure 13 A Typical Flange Mounted Unit Model FGA 300H X Horizontal Gas Analyzer User s Manual 15 Chapter 2 Installation 2 2 7 Operation Voltages The FGA 300H X is wired at the factory for one of four possible operation voltages e 100 VAC e 110 120 VAC e 220 VAC e 240 VAC Note Be sure that the line voltage at the intended installation site corresponds to the factory preset voltage setting CAUTION To change the voltage setting contact the factory for instructions and parts DO NOT make this adjustment on site without first contacting the factory 16 Model F
104. ectrical equipment All procedures should be performed by trained service personnel 4 2 Recommended Calibration Gases To properly calibrate the oxygen sensor and combustibles detector a calibration gas of known composition must be used The following calibration gases are recommended by GE 1 5 O 95 Na calibration gas for oxygen sensor all ranges b zero gas for combustibles c this gas should read 30 0 mV at 700 C 1 292 F Note This gas must be combustibles free even if the analyzer is not fitted with a combustibles detector 2 1000 ppm CO 500 ppm H 1 O2 Balance N a range gas for combustibles b this mixture should read 1500 ppm combustibles Note The presence of the 1500 ppm combustibles will cause the O to read low by 750 ppm IMPORTANT A calibration gas containing only CO is not recom mended since the analyzer will not respond correctly to dry calibration gases that do not contain H Model FGA 300H X Horizontal Gas Analyzer User s Manual 43 Chapter 4 Calibration 4 2 Recommended Calibration Gases cont IMPORTANT The gas cylinders must be certified as to the exact composition of the calibration gas The uncertainty in the oxygen content of the calibration gas is the largest source of error in the calibration process A standard certificate of analysis has an uncertainty in the smaller component of 5 For the oxygen calibration gas this means an oxygen range of 4 75 5 25
105. ed a short on the Display Console circuit board could result in a false 0 00 mV reading 3 A voltage reading of 0 00 mV should be obtained to correspond with the 20 9 oxygen reading If any voltage other than 0 00 mV is measured the Display Console is defective Contact the factory for assistance Note For units fitted with the previous version of the 300D printed circuit board see Appendix F Previous Configurations for the layout of this circuit board 68 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 5 Oxygen Reading Above 20 9 An oxygen display reading greater than 20 9 which may also be indicated by a display reading of 55 35 or the error code E4 is almost always caused by reversed wiring of the oxygen sensor For example 5 oxygen at 700 C would generate an oxygen sensor output of 29 97 mV However reversed oxygen sensor wiring would cause this reading to be 29 97 mV The Nernst equation calculation would then convert this voltage to an oxygen display of 87 36 1 To correct this problem check the oxygen sensor wiring at TB1 in the Accessory Box TB1 in the remote FTC Box and TBI in the Display Console for the correct polarity refer to Chapter 2 Installation 5 2 6 Oxygen Reading Too Low This condition is usually caused by combustibles in the sample gas but it may also be the result of the oxygen sensor being out of calibration To correct the condition complete the foll
106. ed in the field by a fully qualified electronics technician This appendix should be used as a reference for field personnel to make such adjustments To make the first three adjustments above use rotary switches S1 S2 and S3 on the upper portion of the 300D display printed circuit board To access these switches open the Display Console and refer to Figure 48 to locate the switches Figure 48 Rotary Switch Locations Note For units fitted with the previous version of the 300D printed circuit board see Appendix F Previous Configurations for the layout of this circuit board For reconfiguration information not covered in this appendix contact the factory for assistance Model FGA 300H X Horizontal Gas Analyzer User s Manual 117 Appendix A Rotary Switch Settings A 2 Selecting the Display Paramete
107. embly clockwise slightly to clear the flange and carefully pull it straight out of the enclosure as far as the attached leads will allow St Remove the connectors from the 5 pin terminal block TB1 and the 8 pin terminal block TB2 on the FTC board 6 Remove the four screws and washers located in the corners of the old FTC board and lift the FTC board out of the enclosure Note Install the new board in the same orientation as the old board The line voltage and temperature sensor type for the new FTC board are factory set based on the unit s serial number 7 Locate the new FTC board over the standoffs in the enclosure replace the four screws and washers in the corners and tighten the screws securely 8 Reinsert the 5 pin and 8 pin connectors into their corresponding terminal blocks 9 Reinstall the front panel assembly with its four mounting screws 10 Close the cover on the Accessory Box and reconnect the main power to the system 11 Refer to Chapter 4 Calibration and recalibrate the oxygen sensor and the combustibles detector This completes the replacement of the local FTC board Model FGA 300H X Horizontal Gas Analyzer User s Manual 101 Chapter 6 Parts Replacement 6 3 3 Replacing a Remote FTC Board Fuse The Furnace Temperature Control FTC fuse for remote wiring is located on the FTC board CAUTION To replace the FTC board fuse the power to the FGA 300H X must be disconnected Therefore replace the F
108. ement d Both readings should be between 1800 and 1900 ohms and the difference between them should not exceed 50 ohms Disconnect the multimeter and reconnect the common wire to pin 9 of terminal block TB1 If the proper readings are obtained skip to Step 4 below e Ifthe resistance readings are outside the acceptable range the combustibles detector has lost sensitivity and should be replaced See Chapter 6 Parts Replacement for instructions 4 Recalibrate the combustibles detector using the procedures described in Chapter 4 Calibration Be sure to calibrate the detector at the tagged flow rate If the calibration tag is unreadable or has been lost contact the factory for assistance If the steps in this section do not correct the Low Combustibles Reading error contact the factory for assistance 74 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 4 Calibration Responses Chapter 4 Calibration describes the procedures for calibrating the FGA 300H X in great detail However the response of the unit to the calibration procedures can provide valuable clues to potential problems with the installation The three most common situations are described in this section 5 4 1 Everything Is Fine Calibration of the analyzer at the tagged calibration gas flow rate has been successfully completed Upon switching off the calibration gas the analyzer quickly returns to monitoring and displaying th
109. eneral Information 1 2 Display Console The 300D Display Electronics Console is available for use with the FGA 300H X The Display Console can display a variety of system parameters Figure 4 shows a Display Console with both oxygen and combustibles outputs Note A Display Console is required for any FGA 300H X equipped with a combustibles detector The Display Console performs the following functions amplifies the oxygen sensor and combustibles detector outputs e l nearizes the oxygen signal e shows percent oxygen on a four digit LED display e shows ppmy combustibles on a 4 1 2 digit LED display provides a stoichiometric interlock optional Note This device triggers an alarm if the excess oxygen level drops below 100 ppm or the combustibles exceeds 20 000 ppm provides an indication of oxygen sensor resistance provides an indication of convection loop plugging blockages provides an indication of oxygen sensor aging Hag Figure 4 Display Console with O amp Combustibles Model FGA 300H X Horizontal Gas Analyzer User s Manual 5 Chapter 1 General Information 1 3 Principles of Operation Ideally every furnace burner should mix a precise ratio of air to fuel and the mixture should burn efficiently to yield only heat water vapor and carbon dioxide However because of burner aging impe
110. ensor impedance manually complete the following steps 1 Press the mV key located on the keypad of the Display Console and record the voltage reading 2 Simultaneously press the and mV keys located on the keypad of the Display Console and record the voltage reading 3 Ifthe voltage reading from Step 2 is more than 50 the voltage reading from in Step 1 replace the oxygen sensor IMPORTANT The oxygen sensor will continue to take accurate readings for a while after the Blinking Reading error condition occurs but the oxygen sensor should still be replaced as soon as possible Model FGA 300H X Horizontal Gas Analyzer User s Manual 65 Chapter 5 Troubleshooting 5 2 30 Check the Remaining Components BLINKING READING Check O2 Sensor Gett Temp Low No Reading Check Furnace Replace RTD TC OL Reading Good Check FTC VAC Out Check Furnace Wiring OL Reading Replace Furnace Line Voltage No Voltage Defective Display Unit Check FTC VAC In Line Voltage No Voltage eK FIC fue Fuse Good Replace FTC Board Figure 33 Blinking Reading Flow Diagram Continue the troubleshooting sequence shown in Figure 33 by completing the steps beginning with the Check the Temperature Sensor section on page 57 66 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 4 Oxygen Concentration Reads Constant 20 9 This condition is unusual and is likely to be caused either
111. er User s Manual 155 Appendix F Previous Configurations AA RMOSTAT URNACE URNACE 80 VAC IN 80 VAC IN TRANSFORMER N TRANSFORMER L TH 12 Pin Connector plugs into TB1 U3 R36 F CR1 FGA 9 1703 929 Figure 66 FTC Circuit Board Previous ref dwg 1703 929 156 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix F Previous Configurations pasop AIDULUON woy sejgsnquuo UOUJUJO UJJD V SejgnsnquJo5 uedo A DuuJoN WJID Y sejqnsnquuo uedo A puuoN uub y uab xo uowwop uup y USBAXO pesop puuoN woy U
112. following settings for the desired alarm mode Low Alarm install jumper W102 in the 1 2 position High Alarm install jumper W102 in the 2 3 position A high alarm will activate when the combustibles measurement goes over the alarm trip point and a low alarm will activate when the combustibles measurement goes below the alarm trip point 4 Move the jumper at location W101 from the temporary 2 3 position back to its original 1 2 position 36 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 6 Installing Additional Components The typical FGA 300H X Horizontal Flue Gas Analyzer supplied by GE consists of three major components Main Analyzer Unit e Remote FTC Box e Display Electronics Console The instructions in this chapter have explained how to install and wire these primary components However some additional user supplied items are recommended to enhance the system Specifically the following components may make the system more user friendly and improve the overall efficiency and reliability of the system e Flowmeters Pressure Gauges Needle Valves Piping and Fittings Since no two installations are identical it is not possible to provide exact instructions and specifications for this ancillary equipment However the system shown in Figure 24 on page 38 should serve as a good general guideline for most situations This all inclusive diagram is not intended to imply that all
113. g giving full details of the problem and provide the model number and serial number of the instrument If the nature of the problem indicates the need for factory service GE Sensing will issue a RETURN AUTHORIZATION NUMBER RAN and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Sensing instructs you to send your instrument to a service center it must be shipped prepaid to the authorized repair station indicated in the shipping instructions 3 Upon receipt GE Sensing will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken e Ifthe damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e If GE Sensing determines that the damage is not covered under the terms of the warranty or if the warranty has expired an estimate for the cost of the repairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned Model FGA 300H X Horizontal Gas Analyzer User s Manual 165 Warranty no content intended for this page 166 Model FGA 300H X Horizontal Gas Analyzer User s Manual GE DECLARATION Sensing OF CONFORMITY DOC 0035 Rev A We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA declare under our sole responsibility that the FGA300H and
114. g Diagrams and Circuit Boards GNNOYD J9VN3NY J9VN3NY 1V41N3 plugs into TB1 3N 5 Pin Connector 2A SLOBLOW R4 DS1 j LEN JN TA oye S 5 N Oy M 2 N a i R14 R16 R12 R11 Q3sn 10 Q3sn 10 9 Pin Connector plugs into TB2 O1 Q18 91 018 Figure 61 FTC Circuit Board Current ref dwg 703 1271 142 Model FGA 300H X Horizontal Gas Analyzer User s Manual uedo AjJOWON WID Y sejgnsnquuo UOWWOD uupjv SA QISNQUIO pesop A JOWJON uubjv sejqnsnquio uedo puJON wuojy USB AXO uouJuJo WD y uab Axo paso puuuoN WD y USBAXO uonduoseg SAV 138 SEL JO 99190 Sse qnsnquuo Jopaj aq sejqnsnquuo2 Appendix D Wiring Diagrams and Circuit Board
115. he Thermostat aran era alot ERAS C RR HORS ba Ve CT uu cA RE M E E EE OTE 6 3 1 Replacing a Local FTC EE 6 3 2 Replacing a Local FTC Board o o cae toss te ior SUDAN 6 3 3 Replacing a Remote FTC Board use 6 3 4 Replacing a Remote FTC Board dsc anced ibi Display Electron Console s ac nde e pits 6 4 1 Replacing the Display Board FUS 0 cece cece eee eee SPORE POMS hie Ssh its Tact ods toos Dar re Md thia Chapter 7 Specifications 7 1 7 2 7 3 7 4 7 5 General Specifications taria Oxygen a ls EEN Combustibles Specifications a e een dido Avdil ble EE Ordering Afora Le O AN Appendix A Rotary Switch Settings A 1 A 2 A 3 A 4 Ah OIC ASA Ee Ee e Ee Selecting the Display Parameter ss cR be Eie ea hey SR Selecting the Fuel Type o pra Adjusting the Oxygen Channel sse doe nie rats opa reido lora keys Adjusting the Combustibles Channel cse arts ON RENE peels A 5 1 Setting the Scale TVDE dee A EE E A 5 2 Setting the Zero and Full Scale Values Appendix B Outline and Mounting Dimensions Appendix C The Nernst Equation C1 C2 C 5 ET Con prar p To dA OUR PEN SOLAR RENI ORCA PEN SPOOL OTA ER EQUINA CONGMIONS o Pede obo bris The poA SODA EQUOS drei Ee a iS eN etes ue Appendix D Wiring Diagrams and Circuit Boards Model FGA 300H X Horizontal Gas Analyzer User s Manual Contents vii Contents Appendix E Default Settings EN OSI EE 145 E2 EMCCOMPIANCE EE 145 E
116. he four screws in the corners of the new FTC board and tighten them securely Model FGA 300H X Horizontal Gas Analyzer User s Manual 103 Chapter 6 Parts Replacement 6 3 4 Replacing a Remote FTC Board cont 7 Reconnect the connectors to the 5 pin terminal block TB 1 and the 8 pin terminal block TB2 on the new FTC board 8 Close the cover on the remote FTC Box and reconnect the main power to the system 9 Refer to Chapter 4 Calibration and recalibrate the oxygen sensor and the combustibles detector This completes the replacement of the remote FTC board 508s660060608 SA ESE LEE Standard Weatherproof FTC Box E Sa 5 08 8 08880886008 Explosion Proof Flameproof FTC Box Figure 46 FTC Board Location 104 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 4 Display Electronics Console There are no user serviceable components in the Display Console except for the fuse on the display board Refer to Chapter 7 Specifications for the size and type of the display board fuse 6 4 1 Replacing th
117. imately 80 VAC the FTC board and the transformer are functioning properly If the reading is not approximately 80 VAC proceed to the next step Measure the voltage across pins 10 and 11 on the FTC circuit board NOT on TBI of the FTC Accessory Box If the reading is not approximately line voltage check the main power as there is no power reaching the FTC board If the reading is approximately line voltage proceed to the next step Measure the voltage across pins 8 and 9 of terminal block TB1 on the FTC board transformer input If the reading is approximately line voltage proceed to the next step If the reading is not approximately line voltage replace the fuse on the FTC board see the instructions later in this appendix Measure the voltage across pins 6 and 7 of terminal block TB1 on the FTC board transformer output If the reading is approximately 80 VAC the FTC board is defective and must be replaced If the voltage is not approximately 80 VAC the transformer is defective and must be replaced Refer to the instructions later in this appendix for the correct replacement procedures Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix F Previous Configurations N 626 02T 6w53 75
118. in Analyzer Unit 2 Connect the calibration gas and a flowmeter to the calibration gas inlet port If the calibration gas supply does not come with its own regulator a needle valve will also need to be installed 3 Using the flowmeter and the regulator or needle valve set the calibration gas flow rate to the tagged value If the analyzer does not respond correctly at the tagged calibration gas flow rate i e the oxygen sensor millivolt output reading is more than 5 in error the problem is probably due to improper siting of the unit Contact your GE representative for recommendations and or additional hardware CAUTION Make sure the calibration gas flow rate does not exceed 500 cc min 1 0 SCFH Higher flow rates may cool the oxygen sensor below the normal operating temperature and affect the accuracy of measurements or even cause damage to the oxygen sensor IMPORTANT This symbol indicates Caution risk of electric shock AN Model FGA 300H X Horizontal Gas Analyzer User s Manual 45 Chapter 4 Calibration 4 3 1 Regulating the Calibration Gas Flow Rate cont Side View Front View Analyzer Series 00 SS ey WARNING SURFACES ARE VERY HOT KEEP ANALYZER ENERGISED E 5 Calibration Port Standard Weatherproof Enclosure Ll Side View Calibration Port
119. indicates the combustion air requirement index Cl 14 02 0 67 x 02 Combustibility Index This parameter indicates the proportion of air supplied for stoichiometric Air Factor combustion Air factor is often the preferred parameter to control furnaces that are operating from reducing through oxidizing conditions Not Used Not Used Not Used Not Used This key tests the operating condition of the sensor and warns in advance that sensor replacement is necessary Oxygen Sensor Test Model FGA 300H X Horizontal Gas Analyzer User s Manual 41 Chapter 3 Operation no content intended for this page 42 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 4 Calibration Chapter 4 Calibration 4 1 Overview Generally changes in calibration result from sensor detector aging Within limits reading errors can usually be compensated for by making minor calibration adjustments The oxygen sensor should be calibrated every three months and the combustibles detector should be calibrated upon power up and once a month thereafter Since the oxygen sensor and combustibles detector are calibrated differently be sure to proceed to the appropriate section to perform the calibration properly WARNING To ensure safe operation of the FGA 300H X it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations for installing el
120. is A ete RET eR ee eee OC e 14 220 ell OA NEE 15 224 a gato ka a EE 16 ee HERE 17 25 F Selecting EEN 17 29 2 IODC ANE SILE EE EE 17 2 4 Installing the Probe and Probe Sleeve gt eos 19 ds the SV A A EE 20 2 9 L Mo nting thE ARCU PTS rats quce ete zia ba bp Ves aloe kot uM AR ER OU ERI ea tutte E 22 zo MUA Te Remote FIG BOX oe tres e Boc ct Meets c derit Em cd 23 2 5 3 Mounting the Display Electronics Console A e p e es 23 2 5 4 Making WV PUG ONES ee ato d EE ara aai Ro tech 24 2 5 5 Wiring a 300H X eelere e eege ere 26 2 5 6 Wiring a 300H X with IA ee 28 25 7 CONEA RES O er a A Ee 33 25 B ENE CHAO ANS e de tas o de 33 2 6 Installing Additi nal Components issn Atare ect ed ruo A E N 37 Chapter 3 Operation Dill A rcr 39 32 Preventing Common Probe EE 39 let Be E EE EE A0 34 e te Bee EE A0 3 5 BEER eene Keypad EE 41 Model FGA 300H X Horizontal Gas Analyzer User s Manual V Contents Chapter 4 Calibration 4 1 4 2 4 3 44 5 1 5 2 5 3 5 4 IR Pe ATAR AREA EIA Tt PERLE TMT OSE 43 Recommended adlibramat GOSS cs A AAA EA AA EE eae ed 43 elei de IDETTE 45 4 3 1 Regulating the Calibration Gas EE 45 AS eC leet ee EE 47 Calibrating the Combustibles Detector usce cy ee eet nee oc e EE A 50 4 4 1 Checking the Operating Temperature Lov c ice ee E a ae AEN cts 50 LOLA CREEK ee Ra een ee ee Hc IT 52 Ee EE 52 Chapter 5 Troubleshooting IVIVE its EAS AAA TARA AER AAA ER OTA OPERI CREER ER 53 OY O ON Er
121. ker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the FGA 300H Because the sensor furnace power feed in the remote FTC Box must also be interrupted a 4 pole disconnect device is required Note Ifthe instructions in this appendix are followed the unit will comply with the Low Voltage Directive 73 23 EEC Model FGA 300H X Horizontal Gas Analyzer User s Manual 145 no content intended for this page 146 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix F Previous Configurations Appendix F Previous Configurations F 1 Overview Over the years feedback from field installations and advancements in technology have led to refinements in the furnace temperature control FTC circuitry of the FGA 300H X analyzer Specifically the following components within the remote FTC Box have evolved e FIC printed circuit board sensor furnace power transformer Because of the reliability of the FGA 300H X many units with the previous FTC circuitry designs are still in use Therefore troubleshooting and replacement procedures for FTC units fitted with a transformer or a previous version of the FTC circuit board are presented in this appendix FTC Board
122. ks for making power sensor output and temperature control electrical connections In addition for a standard weatherproof system operating in an ambient temperature of 25 to 70 C 15 to 160 F a furnace temperature control FTC circuit board is located in the attached accessory box However for an explosion proof flameproof system or a standard weatherproof system operating at an ambient temperature in excess of 70 C 160 F the furnace temperature control FTC board is located in a remote Furnace Temperature Control FTC Box Model FGA 300H X Horizontal Gas Analyzer User s Manual 3 Chapter 1 General Information 11 Overview cont The furnace temperature control FTC board maintains a constant sensor furnace temperature This temperature stability improves the accuracy of oxygen analysis and extends the life of the oxygen sensor Locate a remote FTC Box as close to the Main Analyzer Unit as possible as long as the ambient temperature at the chosen location is 25 to 70 C 15 to 160 F The remote FTC Box may be ordered as either a standard weatherproof model or an explosion proof flameproof model as shown in Figure 3 300 Standard Weatherproof Model J Explosion Proof Flameproof Model Figure 3 FTC Box Enclosures 4 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 1 G
123. l to each other but the top wrench should be positioned with its end rotated about 2 inches in a clockwise direction from the lower wrench Refer to Figure 41 for a view of the wrenches from both the side and the bottom of the manifold assembly While holding the bottom wrench steady turn the top wrench two inches toward the bottom wrench so that the two wrenches are aligned with each other Do not attempt to move the bottom wrench during the above step Be sure to hold it in its original position 9 Repeat steps 6 8 to loosen the upper nut on the other end of the convection loop see Figure 41 Model FGA 300H X Horizontal Gas Analyzer User s Manual Top ES Wrench Sensor Furnace top view Convection Loop Bottom Wrench Z d Beton E Wrench Wrench Convection Loop Top Wrench Bottom Wrench Sensor Furnace side view Figure 41 Wrench Positions 91 Chapter 6 Parts Replacement 6 2 7a Removing the Old Sensor Furnace cont 10 Unscrew both loosened nuts completely and lift the convection loop off the sensor furnace see Figure 41 on page 91 11 Use a screwdriver to remove the clamp on the bottom of the sensor furnace see Figure 42 WARNING The sensor furnace may still be h
124. laced IMPORTANT Jf the power must be disconnected to replace a part perform the replacement as quickly as possible The FGA 300H X is susceptible to corrosion from acid condensation if it remains without power for more than about thirty minutes If service procedures not covered in this chapter become necessary please contact the factory for assistance WARNING To ensure safe operation of the FGA 300H X it must be installed and operated as described in this manual In addition be sure to follow all applicable local safety codes and regulations for installing electrical equipment All procedures should be performed by trained service personnel IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively Ay A Model FGA 300H X Horizontal Gas Analyzer User s Manual 77 Chapter 6 Parts Replacement 6 2 Main Analyzer Unit Those components associated with the basic sample system are located in the Sample System Compartment This section describes the proper procedures for replacing these parts 6 2 1 Removing the Cover In order to access the sample system components the cover must first be removed from the Sample System Compartment e Standard weatherproof FGA 300H a Remove the blocking screw on one side of the cover see Figure 13 on page 15 b Lift the cover up approximately 20mm 3 4 and then pull it forward off the base e Explosion proof flameproof FGA 300HX
125. lances the concentration gradient Porous coatings of a platinum catalyst on both surfaces of the ceramic cell serve as electrodes while still allowing the oxygen molecules to penetrate the coating and diffuse into the ceramic The measured voltage drop across the cell can be directly related to the ratio of the two oxygen partial pressures by means of the Nernst Equation RT P1 Ey nF o m where F the Faraday 96 484 56 coulombs T absolute temperature K K C 273 15 R gas constant 8 31441 volt coulomb mole K n electrons transferred per molecule 4 mole In natural logarithm 2 303 log p P O partial pressure on reference gas side 0 209 p O partial pressure on flue gas side E voltage on reference face with respect to the flue gas face Model FGA 300H X Horizontal Gas Analyzer User s Manual 137 Appendix C The Nernst Equation C 3 The FGA 300H X Equations The Nernst Equation specifically applicable to the FGA 300H X is obtained by substituting the above values into the general equation converting the natural logarithm to the common logarithm base 10 and converting the units for E42 to millivolts This results in the following equation E mV 0 049605 e T e log kaal P2 The FGA 300H X measures the temperature of the oxygen sensor and automatically inserts the correct value into the Nernst Equation For example at the standard oxygen sensor operating temperature of 700
126. liance iv Error Indicators Combustblesz pi 71 Oyf A aa ee t KR ERE CER RR 55 Fables o ecce cV ADEM UN CM e a E 54 F FTC Board Replacing syst tee en RE 101 103 151 ergeet 63 148 FTC Box Ambient Temperatures adas heey PR 23 Description 3 27 eased Se 4 12 Wines ia ra Cae b Eder dud 23 28 30 Fuel Type Selection Sue Ste EORR EIE 118 Furnace See Sensor Furnace Fuse Display Board Replacing 105 FTC Board Replacing 99 102 150 G Gas Fl ewes EIS 14 H Heaters Replace a Cet aa SA 95 161 Index Information Paragraphs 11 K A sse iria eat n ate tg e 41 L LVD Compliance 4 4 33004540 daa 9 20 145 M Main Analyzer Unit Descriptio sena 10 Mot a ed NE a e dd 22 Removing Covet civic bra iia 78 Wifing sisi at dad 28 Measurements Displaying gt ds SEX A eos 41 Takih EE 40 N Nernst Equation Graphical Form iaa RR ia 138 Numeric Ponti tens oe he Gee et 40 137 O Operating Principles is ora 6 OPA a te Cai a a Me e 111 Ordering Information l l 112 Oxygen Sensor Calibration seee euge mt ex WR a ti E WR 45 Clips Replace 5 worse oe ele Y 79 Descriptions er a lA ao 1 6 Replacing eeh oun a ke 81 Testing 4 oue Aa say ara a 61 Voltage Output ITA rs 47 P Plumbing Leaks cesses Res PES EP RR 67 Power Input os dare PIN um ae eye oe 30 Probe Assembly Description 22 civic bit ERE AS 14 teren eer Sede 19 PUES AMES NS 22 162 R Recorders Analog Output
127. ls needed to replace the combustibles detector To replace the combustibles detector carefully complete the following steps WARNING There are extremely hot surfaces in the Main Analyzer Unit Touching these surfaces could result in serious burns Use heat resistant gloves while replacing the combustibles sensor IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively ANS AS 1 Remove the Sample System Compartment cover as described in the Removing the Cover section on page 78 and locate the combustibles detector on the side of the manifold 2 Open the Accessory Box cover and disconnect the four combustibles detector leads from pins 7 10 of terminal block TB1 there is also a jumper between pins 8 and 9 3 Use a wrench to turn the retaining nut counterclockwise as viewed from the end of the combustibles detector until it comes loose from its fitting see Figure 37 on page 85 4 Slide the combustibles detector out of its housing 5 Thread the wires of the new combustibles detector through the retaining nut so that the threaded end of the nut is facing the combustibles detector body 6 Remove the protective plastic cover from the new combustibles detector Do not touch the two sensing elements on the end of the combustibles detector 84 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 4 Replacing the Combustibles Detect
128. m combustibles B Package Analog D Output Format E CIS 3 0 10 000 ppm combustibles 4 0 2 00 combustibles S Special 0 Single oxygen and single combustibles alarm standard G Alarms configuration 1 Dual oxygen alarms 2 Dual combustibles alarms 114 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 7 Specifications Table 24 FGA 300D Digital Display Ordering Information CATEGORY OPTIONS 0 None Special 2 Tropicalized S Special 1 700 C standard for 300H and 300HX S Special please specify Temperature must match analyzer Temperature Control Setting The information below shows how the FGA Current Output Board Part Number is configured from the options specified FGACB x Table 25 FGA Current Output Board Ordering Information LTR CATEGORY OPTIONS 1 100 VAC 2 110 VAC e Voltage 3 220 VAC 4 240 VAC 1 Supplied loose 2 Mounted with furnace temperature control card C Location 3 Mounted in separate Weatherproof IP65 enclosure 4 Mounted in separate Explosion Proof enclosure S Special 1 0 1 Oxygen 2 0 5 Oxygen 3 0 10 Oxygen p pangs 4 0 20 9 Oxygen 5 0 25 Oxygen S Special 0 None 1 0 1V Output E Special 2 Tropicalized S Special Temperature 0 Factory selected option Control Setting Temperature must match an
129. mbol indicates Caution risk of electric shock AN 20 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 5 Installing the System cont Mount Main Analyzer p 2 13 Es X wo Mount C ipis e Remote FTC Box FIC y p 2 14 Yes Display Console Mount Display Console p 2 15 y No Wire Line Power T O Veg Wire Main Analyzer to Main Analyzer Remote 1525 to Remote FTC Box p 2 18 TCE K p 2 20 Reo Pb Wire Line Power No Display to Remote FTC Box Console p 2 22 Yes DN Wire Main Analyzer Ce No to Display Console SONS ONE rg p 2 18 e dt Yes 1 Wire Line Power Wire Remote FTC Box to Display Console LO Display Console p 2 18 p 2 22 Wire Recorders and or Alarms p 2 25 Install Additional Components p 2 30 Figure 16 Installation Flow Chart Model FGA 300H X Horizontal Gas Analyzer User s Manual 21 Chapter 2 Installation 2 5 1 Mounting the Analyzer After installing the probe and probe sleeve into the analyzer as described in the previous section mount the analyzer as follows 1 Slide a suitable high temperature gasket over the probe assembly so that it rests against the mounting flange on the rear of the main analyzer assembly Note Ifthe mating flange was purchased with the analyzer an appropriate gasket is included 2 Inser
130. measure these two parameters the FGA 300H X uses e a zirconium oxide zirconia oxygen sensor e aplatinum catalyst combustibles detector The oxygen sensor measures excess oxygen or in a fuel rich environment equivalent combustibles The combustibles detector monitors partially combusted fuel only in the presence of excess oxygen 1 e there must be enough oxygen present to burn the fuel Each FGA 300H X may be equipped with an oxygen sensor a combustibles detector or both The FGA 300H X Horizontal Flue Gas Analyzer is available in both the standard weatherproof FGA 300H and the optional explosion proof flameproof FGA 300HX Physically the FGA 300H X standard and explosion proof versions look very different from each other However the internal components and operation are the same for both versions See Figure 1 on page 2 for illustrations of the standard and explosion proof models of the main analyzer unit Both versions of the FGA 300H X include at least a Main Analyzer Unit which consists of the larger Sample System Compartment and the smaller Accessory Box In addition a remote Furnace Temperature Control FTC Box and or a Display Electronics Console may be included in the system Model FGA 300H X Horizontal Gas Analyzer User s Manual 1 Chapter 1 General Information 11 Overview cont Flue Gas Analyzer Series
131. minal block locations and the proper pin connections Table 5 Power Connections To 300D Display TB4 Live L Neutral N Ground a chassis Protective Conductor Terminal 30 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 5 6 Wiring a 300H X with Remote FTC cont 300D Display Electronics Console C a E e En SS 1 oi HEEEH SECH o FTC Board Standard Weatherproof Remote FTC Box
132. n Analyzer Unit to FTC Box Connections From Accessory To Remote FTC Connect Oxygen Sensor Temperature Sensor Combustibles Active Combustibles Reference Power Supply Furnace Since the Main Analyzer Unit receives its power from the Remote FTC Box an interconnection is required 28 Model FGA 300H X Horizontal Gas Analyzer User s Manual A ci ci ci ci OMB ACT OMB ACT OMB REF OMB REF 7 COMBA 9 COMBC 10 COMBR SCREEN ot NZE Sa mz tb ETZ mE 20r atu 293 opo 9ur 2 35 o z 3 S 3 a RTD TC o2 O24 4 RTD TC 3 RTD TC SCREEN amp RTD WIRING USTOMER INTERNAL OXYGEN SENSOR S v o N 3 lt C o Dy 3 x TB3 14 FURNACE 12 NEUTRAL Mains N EARTH 11 LIVE PHASE Standard Accessory Box for remote wiring Explosion Proof Flameproof Accessory Box Chapter 2 Installation FTC Board
133. nction with switch S2 the analog output range is determined by the 2 S3 combination chosen Note The analog output range may only be adjusted for the oxygen channel not the combustibles channel To better understand the interaction between switches S2 and S3 consider the following two examples switch S2 0 and switch S3 1 The S2 setting causes percent oxygen to be displayed and the S3 setting specifies an offset analog output of 4 20 mA 2 10 V to represent an oxygen range of 0 5 see Table 30 on page 120 e switch S223 and switch S321 The S2 setting causes air factor to be displayed and the S3 setting specifies an offset analog output of 4 20 mA 2 10 V to represent an air factor of 0 8 2 0 see Table 31 on page 120 For other S2 S3 combinations refer to Figure 48 on page 117 and follow the directions in Table 29 to set the oxygen channel analog output range either zero based or offset with switch S3 Table 29 Switch S2 Settings Position 0 96 oxygen Position 1 96 excess Fuel Position 2 96 equivalent combustibles Position 3 air factor Position 4 combustibles index Position 5 sensor mV Model FGA 300H X Horizontal Gas Analyzer User s Manual 119 Appendix A Rotary Switch Settings A 4 Adjusting the Oxygen Channel cont Use Table 30 to determine the switch S3 setting if switch S2 is set to position 0 1 or 2 Table 30 Switch S3 Settings S2 0 1 2 0 0 596 0 20 mA
134. nsole and reconnect the main power to the system There are no other user serviceable components in the Display Console If it is suspected that this unit is defective please contact the factory for assistance Model FGA 300H X Horizontal Gas Analyzer User s Manual 105 Chapter 6 Parts Replacement 6 5 Spare Parts In order to perform the service procedures described in this chapter the required spare parts must be purchased from GE WARNING The use of unauthorized spare parts will void the warranty Non factory parts may cause damage to the instrument and or may present a serious safety hazard to the operator For convenience the most commonly needed spare parts for the 300D Digital Display are listed below in Table 20 and for the FGA 300H X in Table 21 on page 107 To purchase any parts whether listed or not contact the factory for assistance Table 20 Spare Parts List 300D Digital Display Part Number Description 1703 001 02 T Linear Board Oxygen Channel 115VAC 1703 001 03 1 Linear Board Oxygen Channel 220VAC 1703 001 04 1 Linear Board Combustibles Channel 115VAC 1703 001 05 1 Linear Board Combustibles Channel 220VAC 1703 001 06 1 Linear Board Oxygen and Combustibles Channel 115VAC 1703 001 07 1 Linear Board Oxygen and Combustibles Channel 220VAC 1703 002 02 1 Display Board Oxygen Channel 1703 002 03 1 Display Board Combustibles Channel 1703 002 04 1 Display Board
135. nt temperature exceeds 70 C the FTC circuit board must be mounted in a Remote FTC Box The Remote FTC Box may be ordered in either a standard weatherproof or explosion proof flameproof enclosure see Figure 10 300 Standard Weatherproof Model Explosion Proof Flameproof Model Figure 10 Remote FTC Box Enclosures 12 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 2 4 Explosion Proof Flameproof Enclosure The explosion proof flameproof FGA 300HX consists of two attached boxes a larger Sample System Compartment that contains the manifold assembly and the sample system and a smaller Accessory Box that contains the analyzer terminal block See Figure 11 The Remote FTC Box shown in Figure 10 on page 12 is also included as part of the explosion proof flameproof system configuration Note With both the standard weatherproof and explosion proof flameproof models an additional box the display console may be included Front View Sample System Compartment Flame Arrestor Cable Gland Calibration I Gas Port A A KS Accessory Box Breather Side View Conduit Holes Probe Sleeve
136. of the components shown are required in every situation Only those items deemed appropriate for the intended application need be considered Note Figure 24 on page 38 shows a system with a 300HX explosion proof flameproof unit a remote FTC Box and a standard Display Console Although other combinations of standard and flameproof enclosures for these components are possible the fundamental connections shown in Figure 24 remain unchanged Model FGA 300H X Horizontal Gas Analyzer User s Manual 37 Chapter 2 Installation 38 Display Electronics Console Cable A f 7 Remote FTC Box Pressure Gauge Flowmeter 1 4 Compression Fitting 1 4 316 S S Tubing Flame arrestor Accessory Box Sample System Compartment Cable Gland A R NR Sous Flame Arrestor gt Shut Off Ball Valve DEI Pressure Gauge 200 500 cc min Flowmeter Needle Valve ES HN TN Calibration Gas Supply Needle Valve Reference Air Supply Figure 24 A Complete Explosion Proof FGA 300 System Model FGA 300H X Horizontal Gas Analyzer User
137. ools as it is pushed from behind by the hot gases still in the furnace The cooled sample gases then drop down the other branch of the convection loop and into the annular space between the probe and probe sleeve where they are carried away by the gas flow in the flue 1 3 1 The Zirconia Oxygen Sensor The inside and outside of the zirconia oxygen sensor see Figure 5 are coated with porous platinum forming two electrodes The sample gas flows past the outside of the sensor while atmospheric air circulates freely on the inside of the sensor This atmospheric air is used as the reference gas for making oxygen measurements See Figure 6 on page 7 Ee A E 37 Ss A ee RS APPS PIII FLEAS E A ae SSS e Figure 5 Zirconia Oxygen Sensor 6 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 1 General Information 1 3 1 The Zirconia Oxygen Sensor cont Oxygen ions migrate through the zirconium oxide along the concentration gradient Sample O2 oo UR oomooomsn Outside Cell smo0ocomsomsoomo s decoocosoo smeooon 4000000moo mooomo ae Atmospheric O5 Inside Cell 20 9 Zirconium Oxide Ceramic with Lattice Imperfections From Outside i From Inside Electrode Electrode When O concentration in sample gas falls the cell voltage rises with increased oxygen migration through the zirconium oxide Figure 6 Oxygen Migration in the Zirconia Sensor At the
138. or cont 7 Insert the new combustibles detector into its housing being careful not to damage the two sensing elements and tighten the retaining nut finger tight 8 Orient the new combustibles detector with the active element above the reference element and the serial number label facing out as shown in Figure 38 on page 86 Using a torque wrench set at 70 N m 600 in Ib securely tighten the retaining nut by turning it clockwise as viewed from the end of the combustibles detector 9 Thread the four 4 combustibles detector leads to the location of terminal block TB1 in the Accessory Box Combustibles Detector Manifold Retaining Nut Figure 37 Combustibles Detector Location Model FGA 300H X Horizontal Gas Analyzer User s Manual 85 Chapter 6 Parts Replacement 6 2 4 Replacing the Combustibles Detector cont 10 Connect the new combustibles detector leads to the appropriate pins on terminal block TB1 in the Main Accessory Box as follows active element leads to pins 7 and 8 reference element leads to pins 9 and 10 jumper between pins 8 and 9 Note The reference element leads are clearly marked with an R on bands located near the ends of the wires 11 Install the Sample System Compartment cover by completing the steps in the Removing the
139. ot Always use heat resistant gloves when handling it 12 Lift the sensor furnace straight up and off the assembly This completes the removal of the old sensor furnace Install the new sensor furnace immediately by completing the instructions in the next section Mounting Screw Figure 42 Removal of Bottom Clamp 92 Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 76 Installing the New Sensor Furnace The new sensor furnace is installed by completing the removal steps in reverse order The specific procedure is as follows 1 Locate the ceramic power block which is on the bottom surface of the new sensor furnace 2 Slide the new furnace into place Make sure the ceramic block is on the bottom Position the furnace so that the mounting hole in the bottom of the furnace lines up with the clamp 3 Screw the clamp back onto the bottom of the furnace see Figure 42 on page 92 Make sure the furnace does not vibrate or shake after you tighten the clamp 4 Replace the temperature sensor RTD and secure it using the clamp For more information on inserting the RTD consult the section Replacing the Temperature Sensor page 87 Convection Loop Torque AS AS l Torque Wrench j f Wrench
140. ote Option J 1 is not required for units with combustibles detectors as the flowmeter is supplied with option B 1 Option J 1 is available for Oxygen only units Note Oxygen sensor types Type 1 is a plasma sprayed cell and is the standard cell Type 2 is a coated plasma sprayed cell intended for applications where percent levels of CO are expected Model FGA 300H X Horizontal Gas Analyzer User s Manual 113 Chapter 7 Specifications 7 5 Ordering Information cont The information below shows how the FGA 300D Part Number is configured from the options specified 300D gt S a Table 24 FGA 300D Digital Display Ordering Information CATEGORY OPTIONS 0 No enclosure OEM 1 Weatherproof enclosure IP65 2 Rack mount 3 Bench mount 4 Panel mount 7 Flameproof enclosure II 2 G EEx d IIC T6 8 Flameproof enclosure with FTC II 2 G EEx d IIC T6 9 304SS Weatherproof enclosure IP65 S Special 1 100 VAC 2 110 120 VAC c power 3 220 VAC 4 240 VAC 1 0 20mA output 2 4 20mA output 3 0 10 VDC output S Special 0 None 1 0 5 Oxygen 2 0 10 Oxygen 3 0 20 Oxygen E Zirconia 4 0 25 Oxygen Range 5 0 1000mV Cell mV 6 0 8 1 2 0 8 2 0 Air factor Specity fuel 7 5 10 20 25 Excess fuel SES 8 5 10 20 25 Equivalent combustibles S Special 0 None 1 0 2 000 ppm combustibles Combustibles 2 0 5 000 pp
141. owing steps 1 The sample gas may be contaminated with combustibles from the following two common sources grease or oil in the sensor plumbing silicon based plumbing tape excess fuel in the burner The oxygen sensor will cause combustibles such as CO H3 or hydrocarbons in the sample to react with oxygen thus depleting the oxygen in the sample gas This will give a reading that may be less than the expected amount of oxygen To fix the problem remove the source of the contamination 2 Ifthesample gas is not contaminated with hydrocarbons recalibrate the oxygen sensor See Chapter 4 Calibration for the correct procedure Model FGA 300H X Horizontal Gas Analyzer User s Manual 69 Chapter 5 Troubleshooting 5 2 7 Oxygen Reading Too High This condition is most likely caused either by poor quality reference air a leak in the plumbing or an oxygen sensor that is too cool A brief description of possible solutions to this problem is presented below WARNING The main analyzer enclosure is hot Use heat resistant gloves when handling the enclosure IMPORTANT This symbol indicates Caution risk of electric shock AN A plumbing leak permits contamination of the reference air by the flue gas sample The resulting reduction in the ratio of the oxygen partial pressures reduces the mV output from the oxygen sensor and yields a percent oxygen reading that is higher than expected Use the following steps to remedy the problem
142. r Switch S2 allows the selection of the combustion process parameter to be automatically displayed Note The 300D can automatically display only one parameter at a time Therefore only the display parameter selected with switch S2 is automatically displayed Refer to Table 27 and use switch S2 to select the preferred automatic display parameter Table 27 Rotary Switch S2 Settings Default Display Parameter Oxygen Excess Fuel Equivalent Combustibles Air Factor Combustibles Index Sensor mV A 3 Selecting the Fuel Type Switch S1 allows the selection of the appropriate fuel type for installation However switch S1 is used in conjunction with switch S2 and it is applicable only to the following three display parameters as chosen with switch S2 e Excess Fuel e 46 Equivalent Combustibles e Air Factor If switch S2 is used to automatically display any other parameter switch S1 has no effect Use Table 28 to determine the correct setting for switch S1 Table 28 Rotary Switch S1 Settings 0 il 2 3 4 Coal Oil Propane Butane Natural Gas Coke Oven Gas 118 Model FGA 300H X Horizontal Gas Analyzer User s Manual Appendix A Rotary Switch Settings A 4 Adjusting the Oxygen Channel While switch S2 is used to select the parameter displayed switch S3 permits selection of the analog output range for the parameter being displayed Since switch S3 is used in conju
143. reading to drop proceed to the next section 3 Ifthe oxygen reading drops in Step 2 above ensure that all fittings are tight and replace the Sample System Compartment cover If the oxygen reading gradually returns to 20 9 try tightening the fittings an additional 1 8 turn If the problem persists contact the factory for assistance CAUTION Do not tighten fittings more than 1 8 turn at a time Model FGA 300H X Horizontal Gas Analyzer User s Manual 67 Chapter 5 Troubleshooting 5 2 4c Check the Display Electronics Console If the shorted wiring and plumbing leak checks have not corrected the problem complete the following steps 1 Disconnect the oxygen sensor leads from pins 2 and 3 of terminal block TB1 in the Display Console See Figure 34 for the location of TB1 Figure 34 Display Electronics Console TB1 2 Connect the positive lead of a digital voltmeter to the wire removed from pin 2 and connect the negative voltmeter lead to the wire removed from pin 3 IMPORTANT The oxygen sensor leads must be removed from the terminal block for this test If the leads are not disconnect
144. rfect air to fuel mixtures and changing firing rates this rarely happens Monitoring the actual efficiency of the combustion process is easily accomplished with the FGA 300H X A flue gas sample is drawn into the probe by gaseous diffusion and a gentle convective flow The sample passes through the probe and into the sample system where it is maintained at a temperature above 200 C 392 F by the heater block In the presence of oxygen this sample temperature is high enough to burn any partial combustion products that reach the active platinum coated element of the combustibles detector The resulting temperature differential between the two combustibles detector elements is related to the concentration of partial combustion products in the test sample Note The sampled gas is maintained above 200 C 392 F to prevent flue gas acids from condensing in the analyzer and causing corrosion The sample then passes into the sensor furnace which heats the sample gas and the oxygen sensor to 700 C 1 292 F a temperature above 650 C 1 202 F is required for proper operation of the oxygen sensor The oxygen sensor is covered with a platinum catalyst that burns all remaining combustibles enabling the sensor to measure the excess oxygen or fuel in the flue gas The sensor furnace also generates the convective flow that circulates the sample gas through the sample system The hot sample gas in the sensor furnace rises out of the furnace and c
145. rocedures Note The zero and full scale analog output values must be set after selecting a linear or offset scale Specify the desired scale type by installing jumper W103 in one of the following positions see Figure 49 on page 122 e position 1 2 for a linear scale 0 20 mA or 0 10 V or position 2 3 for an offset scale 4 20 mA or 2 10 V A 5 2 Setting the Zero and Full Scale Values Setting the zero and full scale values is the second step in setting up the analog outputs Please keep in mind that the scale type zero based or offset should be selected before setting the zero and full scale values Since the procedures for the two scale types are different proceed to the appropriate section to set the output values refer to Figure 49 on page 122 A 5 20 ALinear Scale To set the zero and full scale values for a linear scale complete the following steps see Figure 49 on page 122 Connect two identical resistors of between 1800 and 2000 ohms across terminal block TB1 pins 5 6 and pins 6 7 Install a jumper on pins 1 and 2 of W103 Adjust potentiometer R111 for the desired full scale value as read on the front panel display Adjust potentiometer R129 until the analog output corresponds to the value on the front panel display Un Aa oU N E Remove the resistors from TB1 and the jumper from W103 Note For units fitted with the previous version of the 300D printed circuit board see Appendix F Previous Configura
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147. steps in the Removing the Cover section on page 78 in reverse order Reconnect the main power to the unit and recalibrate the oxygen sensor as described in Chapter 4 Calibration Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 8 Replacing the Cartridge Heaters A heater block is mounted on the end of the 300H X Main Analyzer Unit The cartridge heaters 3 1 2 long cylinders and a thermostat are located inside this heater block see Figure 44 Thermostat d Heater Block Manifold Convection Loop Top View Figure 44 Thermostat and Heater Locations The following items are required to replace the cartridge heaters e wire cutters wire strippers e Watlube Heat Transfer and Release Agent CAUTION To replace the cartridge heaters the power to the FGA 300H X must be disconnected Therefore replace the cartridge heaters and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation WARNING There are extremely hot surfaces in the Main Analyzer Unit If they are touched serious burns could result Always use heat resistant gloves when replacing the cartridge heaters To replace the cartridge heaters complete the following steps IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively Al AN Model
148. t flow rate 1 Introduce the zero combustibles gas into the calibration gas inlet port on the Main Analyzer Unit The oxygen span gas which consists of 5 O and 95 N gt may also be used for the zero combustibles gas This reduces the number of gas cylinders required to calibrate the analyzer and the two adjustments may be made simultaneously 2 Verify that the 300D Display reads 0 ppmy If the 300D Display does not read 0 ppmy adjust the trimmer potentiometer R111 on the 300D Display printed circuit board Since R111 is very sensitive adjustments should be made in small increments Refer to Figure 27 on page 51 for the location of R111 and adjust it in the appropriate direction e Turn R111 clockwise to increase the ppmy reading or e Turn R111 counterclockwise to reduce the ppmy reading If the 300D Display can not be adjusted to read 0 ppmy the combustibles detector must be replaced 4 4 5 Span Check To perform a span check complete the following steps 1 Introduce the span calibration gas A span calibration gas consisting of 1000 ppmy CO 500 ppmy H 1 O balance N is recommended 2 The combustibles reading should be approximately 1500 ppmy for the gas specified in the previous step Note During this procedure the oxygen reading will be low because the oxygen sensor measures excess oxygen and the combustion of the span calibration gas consumes 750 ppmy of the oxygen If the reading is incorrect a
149. t the probe and sleeve into the hole in the furnace boiler wall until the gasket is sandwiched between the two flanges Secure the analyzer in place by fitting bolts into the matching flange holes and fastening the bolts with washers and nuts Upon insertion the two flanges should fit together with the gasket clamped between them see Figure 15 on page 20 CAUTION To prevent corrosion the analyzer must be powered up immediately after being mounted and 22 the power must remain on at all times If the power must be removed for more than thirty minutes purge the analyzer through the calibration port with a continuous flow of instrument air at a minimum rate of 150 cc min 0 3 SCFH An explosion proof flameproof analyzer requires a constant reference air flow Connect a 50 cc min atmospheric air line 20 9 oxygen to the purge connection see Figure 17 Reference Purge Air Inlet Top View Pre Sealed Cable Gland m Main Analyzer Unit Calibration Gas Inlet Pre Wired Accessory Box Figure 17 Explosion Proof Flameproof Enclosure Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 2 Installation 2 5 2 Mounting the Remote FTC Box In addition to the Main Analyzer Unit and the attached Accessory Box the 300H X system may include a separate Remote FTC Box If so mo
150. tage Readings Voltage Reading Recommended Action The FTC board is good The Display Electronics Console may be defective contact the factory for assistance Approximately full line voltage Voltage greater than 0 The FTC board is defective and must be replaced See Chapter 6 Parts Replacement but less than full line voltage No voltage present Proceed with the remaining steps in this section 3 Using a digital multimeter measure the FTC board s AC input voltage across pins 1 and 2 of terminal block TB1 on the FTC board See Figure 32 on page 63 for the location of TB1 One of the conditions listed in Table 19 should occur Table 19 FTC Output Voltage Readings Voltage Reading Recommended Action Approximately full line voltage Continue with the next step in this section No voltage present There is no power reaching the FTC box check the power source 4 Remove the FTC board fuse see Figure 32 on page 63 and check it for continuity If the fuse is blown replace it with a new fuse of the size and type listed in Chapter 7 Specifications 5 Ifthe FTC board fuse is good the FTC board is defective and must be replaced See Chapter 6 Parts Replacement for instructions 5 2 1 Blinking cont If the instructions provided in this section have not resolved the problem contact the factory for assistance Note Older FGA 300H X units may have a different FTC board and or a sensor furnace power tr
151. ted within 1 8 m 6 ft of the unit Because the sensor furnace power feed in a remote FTC Box must also be interrupted a 4 pole disconnect device is required for units so equipped This does not apply to the flameproof 300HX IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively WARNING Power up the FGA 300H X as quickly as possible after installation If the analyzer is left installed without power the unit s components become susceptible to acid condensation that will cause corrosion Be sure to observe all installation limits and precautions described in this chapter Pay particular attention to the temperature limitations for the Furnace Temperature Control FTC Board WARNING To ensure safe operation of the FGA 300H X the unit must be installed and operated as described in this manual Also be sure to follow all applicable local safety codes and regulations for installing electrical equipment All procedures should be performed by trained service personnel Model FGA 300H X Horizontal Gas Analyzer User s Manual 9 Chapter 2 Installation 2 2 Configuration Options 2 2 1 Standard Weatherproof Enclosure The standard weatherproof configuration consists of two attached boxes the Sample System Compartment which houses the manifold and the sample system and the smaller Accessory Box with a front window for viewing the operation light which contains the terminal
152. tep 2 WARNING There are very hot surfaces in the Main Analyzer Unit Touching any of these surfaces without heat resistant gloves will result in serious burns 1 Disconnect the Main Analyzer Unit RTD leads from pins 3 and 4 of terminal block TB1 in the Remote FTC Box a Using a digital multimeter measure the resistance across the disconnected RTD leads One of the conditions listed in Table 12 on page 58 should occur Model FGA 300H X Horizontal Gas Analyzer User s Manual 57 Chapter 5 Troubleshooting 5 2 16 Check the Temperature Sensor cont Table 12 RTD Resistance Readings Resistance Reading Recommended Action 360 370 ohms The temperature is good proceed to the oxygen sensor check less than 360 ohms The temperature is low proceed to the sensor furnace check open loop OL The RTD is defective and must be replaced see Chapter 6 Parts Replacement b Complete the action recommended in Table 12 Note Ifa resistance reading other than those listed above is obtained refer to Table 13 to determine the operating temperature of the sensor furnace A standard FGA 300H X operates at a temperature of 700 C Table 13 RTD Resistance vs Temperature Resistance vs Temperature for 100Q Platinum RTD Sensor Example An RTD resistance of 200 ohms indicates a sensor furnace operating temperature of about 270 C First find the resistance value in the table 201 30 that best matches the measure d valu
153. teps IMPORTANT This symbol indicates Caution risk of electric shock AN 1 Remove the cover from the Sample System Compartment and inspect the installation of the combustibles detector Verify that the serial number label on the detector is in the 9 o clock position which indicates that the two elements are positioned with the active element above the reference element Refer to Chapter 6 Parts Replacement for detailed installation instructions for the combustibles detector 2 Remove the combustibles detector and inspect the two elements The active and reference elements should be parallel to each other and approximately 5 32 in 4 mm apart If the elements are too close together heat will transfer from the active element to the reference element and lower the output signal If the active element is bent outward some of its heat may be transferred to the manifold structure and lower the output signal 3 Reinstall the combustibles detector as described in Chapter 6 Parts Replacement Test the combustibles detector by completing the following steps a Inthe Accessory Box disconnect the common wire from pin 9 of terminal block TB1 and attach one lead of a multimeter to the disconnected wire b Attach the other lead of the multimeter to pin 10 of terminal block TB1 and record the resistance of the reference element c Move the multimeter lead from pin 10 to pin 7 of terminal block TB1 and record the resistance of the active el
154. the vicinity of the sample point 2 3 2 Preparing the Site Preparation of the installation site should include the following steps see Figure 14 on page 18 1 Atthe chosen analyzer location on the furnace or boiler wall or on the side of a horizontal or vertical flue duct drill a hole of the proper diameter to accommodate a short length of pipe having at least a 4 8 cm 1 875 in inside diameter A 2 in length of Schedule 80 pipe is recommended for this purpose 2 Weld the short pipe into the hole The pipe should be long enough to provide at least a 10 cm 4 in clearance between the mounting surface and the mating flange installed in the next step Note For installation in a masonry wall the short pipe should extend through the wall to prevent the probe and sleeve from becoming trapped if the wall should crumble 3 Weld a mating flange onto the pipe section This flange as well as a mounting flange for the Main Analyzer Unit and a suitable flange gasket may be ordered with the FGA 300H X to ensure a proper match of the mounting components Model FGA 300H X Horizontal Gas Analyzer User s Manual 17 Chapter 2 Installation 2 3 2 Preparing the Site cont Front View Side View 10 2 cm 4 Min 4 8 cm i 1 7 8 Min Masonry Wall GAS FLOW Mounting Plate 2 Sch 80 Pipe Mating Flange Figure 14 Installed Pipe and Mating Flange
155. the inner clip pinch the ends together and pull the clip out of the oxygen sensor The outer clip is easily removed by pulling it away from the oxygen sensor body Model FGA 300H X Horizontal Gas Analyzer User s Manual 81 Chapter 6 Parts Replacement 6 2 3 Replacing the Oxygen Sensor cont 82 Sensor Body aJ Fitting Nut Washer Figure 36 Partially Removed Oxygen Sensor Model FGA 300H X Horizontal Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 2 3 Replacing the Oxygen Sensor cont 3 While wearing heat resistant gloves slowly unscrew the fitting nut until it is completely free of its fitting Carefully pull the oxygen sensor out of the sensor furnace making sure that the sensor does not hit the sides of the furnace during its removal Figure 36 on page 82 shows an oxygen sensor that has been partially removed Lubricate the threads of the new oxygen sensor GE recommends the use of Molykote High Temperature Non Silicon Lubricant for this purpose When replacing the oxygen sensor handle it only by the fitting at its base Carefully insert the new sensor into the bottom of the sensor furnace Do not allow it to touch the sides of the sensor furnace IMPORTANT Jf the sensor furnace is hot insert the new oxygen sensor slowly T
156. the thermostat the power to the FGA 300H X must be disconnected Therefore replace the thermostat and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation WARNING There are extremely hot surfaces in the Main Analyzer Unit If they are touched serious burns could result Always use heat resistant gloves when replacing the thermostat IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively AN A Model FGA 300H X Horizontal Gas Analyzer User s Manual 97 Chapter 6 Parts Replacement Removing the Old Thermostat Use the following procedures and refer to Figure 44 on page 95 to complete the thermostat replacement 1 2 3 4 Disconnect the main power to the FGA 300H X Remove the Sample System Compartment cover as described in the Removing the Cover section on page 78 Access terminal block TB4 by Moving the Front Panel Assembly on page 89 The thermostat is located next to one of the cartridge heaters in the heater block near the bottom of the Sample System Compartment The thermostat wires come out the top of the heater block Trace the thermostat wires from the end of the thermostat to pins 12 and 13 on terminal block TB4 in the Accessory Box Disconnect the two wires which correspond to the thermostat Be sure to disconnect ONLY the thermostat wires at pins 12 and 13 on terminal block TB4 IMPORT
157. tion on these units 6 3 1 Replacing a Local FTC Fuse The Furnace Temperature Control FTC fuse for local wiring is located on the front panel assembly inside the Accessory Box CAUTION To replace the FTC fuse the power to the FGA 300H X must be disconnected Therefore replace the FTC fuse and reconnect the power as quickly as possible to prevent corrosion of the analyzer components due to acid condensation IMPORTANT This symbol indicates Caution risk of electric shock GS The only tool needed to replace the FTC fuse is a screwdriver Refer to Figure 45 on page 100 and complete the following steps to replace the FTC fuse 1 Disconnect the main power to the unit 2 Open the hinged cover on the standard Accessory Box 3 Locate the fuseholder on the front panel Using a screwdriver remove the spring loaded cover from the fuseholder and discard the old fuse 4 Install a new fuse of the same type and size see the label near the fuseholder or Chapter 7 Specifications and reinstall the fuseholder cover 5 Close the cover on the Accessory Box and reconnect the main power to the system The system may now be placed back into service Model FGA 300H X Horizontal Gas Analyzer User s Manual 99 100 Chapter 6 Parts Replacement 6 3 1 Replacing a Local FTC Fuse cont FTC Board behind FTC Fuse H
158. tions for the layout of this circuit board Model FGA 300H X Horizontal Gas Analyzer User s Manual 121 Appendix A Rotary Switch Settings A 5 2 Setting the Zero and Full Scale Values cont Ceceecccccccce vcor nn o
159. to the FTC terminal block TB1 located in the Accessory Box Refer to Figure 18 on page 25 Figure 19 on page 27 and Table 1 for pin connections Table 1 Display to Local FTC Box Connections Display Pin Accessory Box Connect TB1 Pin TB1 Oxygen Sensor Oxygen Sensor Combustibles Detector Reference Combustibles Detector Common Combustibles Detector Active Display Screen 2 5 56 Connecting the Power Power must be connected to both the display and the analyzer Use Figure 18 on page 25 Figure 19 on page 27 and Table 2 to make connections Table 2 Power Connections To Accessory To 300D Display From Voltage Supply Box TB3 TB4 Live 11 Live Phase 2L Neutral 12 Neutral 1N Ground a Earth chassis Protective Conductor Terminal 26 Model FGA 300H X Horizontal Gas Analyzer User s Manual SSEER Chapter 2 Installation Console 300D Display TB3 RELAYS TB2 OUTPUTS COMB 02 NO C NC NO C NC 6 5 4 3 2 1 Gs E5 VSET E7
160. ts must be set Refer to Table 7 and Figure 22 on page 32 to make the proper connections Table 7 Alarm Connections Alarm Output 300D Display Pin TB3 1 Oxygen NC Oxygen C Oxygen NO Combustibles NC Combustibles C Combustibles NO The next step before using the alarms is setting the alarm trip points for both the oxygen and combustibles channels Proceed to the appropriate section below to set the desired alarm trip points Model FGA 300H X Horizontal Gas Analyzer User s Manual 33 Chapter 2 Installation 2 5 8 Connecting Alarms cont 2 5 8a Setting the Oxygen Alarm Trip Point The instructions in this section describe the two steps required to properly set the oxygen alarm trip point Set the alarm trip point to the desired oxygen percentage e Set the oxygen alarm as either a high or low type Switch S4 on the 300D Display printed circuit board is used to select the alarm trip point Each position on switch S4 represents a percentage of the recorder s full analog output range which is set at the factory using switch S3 1 Use the following formula to determine the correct analog output trip point and refer to Table 8 and Figure 23 on page 35 to adjust switch S4 to the required position Trip Point O2 FullScaleO2 09 Trip Point For example if an alarm trip point of 6 oxygen is desired use the above equation to find the trip point 60 of full scale range Trip
161. unt the remote FTC Box as close to the analyzer as possible and connect it to the Accessory Box with 0 75 mm or 18 awg cable for distances up to 25 meters 80 feet Note The remote FTC Box may be located up to 40 meters 110 feet from the Accessory Box if 1 mm or 16 awg cable is used The ambient temperature of the mounting location should not exceed 70 C 160 F If the ambient temperature at the proposed location is expected to exceed 70 C 160 the enclosure should be located where the temperature will be within the remote FTC s specified temperature limits of 25 to 70 C 15 to 160 F Refer to Appendix B Mounting Dimensions and Drawings for the Main Analyzer Unit and Remote FTC Box mounting dimensions 2 5 3 Mounting the Display Electronics Console Ideally the 300D Display Electronics Console should be located within 5 meters 15 feet of the FTC Board However the use of shielded cable permits distances up to 150 meters 500 feet for units equipped with both the oxygen sensor and combustibles detector If a greater distance is required contact the factory for assistance See Appendix B Outline and Mounting Dimensions for the Display Electronics Console mounting dimensions Note For units without the optional combustibles detector the Display Console may be located up to 600 meters 2 000 feet from the FTC Board without significant signal degradation if shielded cable is used The Display Console has four
162. ure that he operates all auxiliary equipment in accordance with local codes standards regulations or laws applicable to safety Working Area WARNING Auxiliary equipment may have both manual and automatic modes of operation As equipment can move suddenly and without warning do not enter the work cell of this equipment during automatic operation and do not enter the work envelope of this equipment during manual operation If you do serious injury can result WARNING Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform maintenance procedures on the equipment Qualification of Personnel Make sure that all personnel have manufacturer approved training applicable to the auxiliary equipment Personal Safety Equipment Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment Examples include safety glasses protective headgear safety shoes etc Unauthorized Operation Make sure that unauthorized personnel cannot gain access to the operation of the equipment Model FGA 300H X Horizontal Gas Analyzer User s Manual iii Preface Environmental Compliance Waste Electrical and Electronic Equipment WEEE Directive GE Measurement amp Control Solutions is an active participant in Europe s Waste Electrical and Electronic Equipment WEEE take back initiative directive 2002 96 EC The equipment that you bought has required the
163. ush a thin coat of a heat transfer agent on the new cartridge heater GE recommends Watlube Heat Transfer and Release Agent 2 Pass the wires on the new cartridge heater down through the heater block slide the new cartridge heater into place and feed the wires to terminal block TB4 in the Accessory Box 3 Strip the ends of both cartridge heater wires 4 Crimp connectors onto the wires 5 Connect each of the wires to the appropriate terminals on TB4 see Figure 40 on page 89 75W heater wires to terminals 11 and 13 150W heater wires to terminals 11 and 12 6 Replace the Accessory Box front panel by completing the steps in the Moving the Front Panel Assembly section on page 89 in reverse order 7 Install the Sample System Compartment cover by completing the steps in the Removing the Cover section on page 78 in reverse order and reconnect the main power to the unit This completes the replacement of the cartridge heaters 6 2 9 Replacing the Thermostat The thermostat which is approximately the same length as the heater block is located in the heater block at the end of the Main Analyzer Unit The thermostat regulates the temperature of the heater block to approximately 225 C If the thermostat is defective or it is removed the heater block will quickly cool down The following items are needed to replace the thermostat wire cutters wire strippers e Watlube Heat Transfer and Release Agent CAUTION Toreplace
164. y hot surfaces and risk of electric shock respectively Ay A A standard screwdriver is the only tool needed for replacement of the temperature sensor Complete the following steps in the order shown to replace a defective temperature sensor 1 Disconnect the main power to the FGA 300H X 2 Remove the Sample System Compartment cover as described in the Removing the Cover section on page 78 3 Open the Accessory Box cover and disconnect the temperature sensor leads from pins 3 and 4 on terminal block TBI 4 Loosen the clamp that holds the temperature sensor to the bottom of the sensor furnace 5 Extract the temperature sensor from the top of the sensor furnace See Figure 39 on page 88 which shows a partially removed RTD type temperature sensor the TC type temperature sensor is mounted and removed in a similar manner IMPORTANT Although the RTD and TC type temperature sensors are mounted and wired in the same manner they are electrically different DO NOT substitute one type in a unit configured for the other type 6 Insert the new temperature sensor into the sensor furnace being careful not to strike it against the heating element or the pipe wall inside the sensor furnace Model FGA 300H X Horizontal Gas Analyzer User s Manual 87 Chapter 6 Parts Replacement 6 2 5 Replacing the Temperature Sensor cont 7 Tighten the clamp to secure the new temperature sensor to the top of the sensor furnace 8 Thread the

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