MGA6010 Manual - Super Systems Europe
Contents
1. 20 Pertormime a Span ea eA aad 21 Calibrating the Oxygen arses 22 Automatic Sampling 22 COF PF Adjustment Incremento eese inire aseo Poe th eI uo pea 23 COF PF Adjustment Interval minutes dein eet tede daa iode 23 Minimumi C OI BEY 23 Maximum COF J PE Value toit 23 COP PE AdJ StmenttriMode usa l uns adr as OM pace ande 23 Communications SS CUD a ER 0 aunt 24 IP A eu Meta uud 24 Set RS485 Communications eco e eerte eec cei di des aeta gn geben ce 25 I M M 26 reir a ee 27 28 General Setup 28 Security NEP gis 28 Factory Default Se NSS 00 uay 28 Groans 28 re an t iti cde assis 20 Auto Calibration Setup u tti nein V a EXHI 30 Method 1 Automatic calibrations based on timed intervals 30 Method 2 Automatic calibration based on digital inputs 31 Gas Alarm D RP 31 Instrument ite pd D a E UT ah a Es RUE Wa UNS Prater 32 General Informal OB a ossi un u uui ug a ands 32 6 Dates aa s 32 MGA 6010 Operations Manual Rev Page 1 of 41 intense uet dates es aera asa Poe ell 33 Database Maintenanc2. 0 08 0 02 7 11 AM 0 00 C 1700 F 0 020 59 6 47AM 735 8 23 The Zoom option will allow the user to zoom in on a particular part of the screen Once this has been selected the user can take a stylus or a finger and create a box around the desired data Once the user releases the stylus or finger a zoom is no longer possible and the user will need to re select the option from the sub menu to zoom in again bd 20095C 704 AM 8 04AM 9 04AM 10 04AM MGA 6010 Operations Manual Rev Page 12 of 41 The Restore option will back out of any zoom options that have been performed and display the chart screen as it initially was The Add Note option allows the operator to enter a note on the chart similar to writing on a paper chart The note shows up when the chart is printed out using the utility software included with the Series 9010 instrumentation Pressing the Add Note option displays a screen where the operator can enter the operator ID or initials and a note The user has the option to enter a note using the operator interface keyboard where he or she will be able to type in the note or the user can use the Signature mode which will allow them to write a note using a stylus The Data option will show the trend data as a data grid instead of the trend lines on a chart This functionality is exactly the s
3. 6 18 2011 6 16 2011 2 32 23 PM 502 15 19 2011 8 11 30 5 19 2011 10 41 40 PM 1586 Lindberg 5 17 2011 10 19 41 AM 5 17 2011 2 40 26 PM 1586 Lindberg Return This screen will identify sessions between the date range specified at the top of the screen Asa default sessions from the past 24 hours are shown By expanding the data range additional sessions can be seen These sessions are sorted with the newest entry at the top but they can be sorted by End Time Equipment Name or Operator Name by touching the header of each column EE 40221 4703445718 Eek ec 2 12 2010 P 11 05 AM 3 1 60 170100 F 1 110 1 20 C 12 15 0 80 C 0 40 C M x 10 16 10 26 10 40 AM 10 52 AM 11 04 AM To see the details of any session highlight it by touching it and then press Detail This will take you to a graphical representation of the data from the selected session MGA 6010 Operations Manual Rev Page 17 of 41 For more information on navigating the Chart Screen see the Chart section of this manual To leave the Chart view press the red X in the upper right hand corner of the screen Pump Control The Pump Control screen will identify and allow the modification of the pump state On or Pump Control Pump Status Pump On Delay seconds Pump Off Delay seconds Return MGA 6010 Operations Manual Rev Page 18 of 41 Sen
4. CO CO and CH in heat treat furnace atmosphere gases It uses a color touch screen display operator interface for data entry and for viewing Selections can be made on the screen using a finger or a stylus Do not use objects such as screwdriver tips or ink pens on the screen since they can potentially cause permanent damage When the instrument is powered on it will take approximately 30 seconds for the MGA6010 software to automatically load After that the instrument is ready to use When the power switch is turned off the instrument initiates a controlled shutdown procedure which takes about 15 seconds After the controlled shutdown period the instrument will completely turn off When the power switch is turned on the MGA6010 will initiate the startup procedure When finished the main screen will be displayed 40221 4518503125 0 20 97 0 611 Menu A Measured values of CO CO and CH B Pump status indicator Button for change pump status C Button to access menu list D Session status indicator E Temperature Instrument Temperature indicator F Button to Carbon Calculation screen MGA 6010 Operations Manual Rev Page 8 of 41 G Automatic Carbon Calculation Adjustment indicator H External instrument Communications status indicator Measured value of Oxygen J Button for Trend Chart screen K Numeric flow indicator L Visual Flow indicator This screen is the default screen
5. To change the port usage enter a number between 0 and 2 The possible values are Modbus Master Modbus Host Port Baud Rate This is the speed of communications which can range between 1200 and 115200 Probe Temp mV Instrument Type This is the make and model of the device that will be supplying the instrument with information on probe temperature probe millivolts and COF PF Possible choices are SSi AC20 Yokogawa UDP750 Honeywell UDC3300 Dualpro Loop 1 Modbus Dualpro Loop 2 Modbus SSI 9200 Loop 1 Probe Temp mV Instrument Address This is the address of the atmosphere controller It can be directly entered using the numeric keypad on the touch screen MGA 6010 Operations Manual Rev Page 25 of 41 Furnace Temp Instrument This is the make and model of the device that will be supplying the instrument with information on furnace temperature If there is no instrument associated with this input the probe temperature will be used Possible selections are SSi AC20 Yokogawa UDP750 Honeywell UDC3300 Dualpro Loop 1 Modbus Dualpro Loop 2 Modbus SSI 9200 Loop 1 SSI 9200 Loop 2 SSI 9200 Loop 3 SSI 9100 Loop 1 Furnace Temp Instrument Address This is the address of the furnace temperature instrument It can be directly entered using the numeric keypad on the touch screen Probe Temp mV Source Instrument This line displays the status of communications with the Temperature Millivolt instrument The message is automatica
6. a specific direction and they display only slight movements up and down This should take approximately 45 seconds There is a column showing the Status of each gas In this area the instrument is making a comparison between the Target value and the Actual value and providing feedback based on the amount of difference between the two There are three possible words that can appear in this area OK The gas is within 1096 of where it is expected to be OK The gas is between 1096 and 2096 of where it is expected to be This could indicate an issue with the calibration gas so the calibration gas and the associated tubing should be checked and verified to be free from leaks or improper gas composition This message does not necessarily indicate that there is a problem with the sensor or the calibration It is meant only to have the operator make sure that the proper procedures are being followed BAD The gas is more than 2096 from where it is expected to be The same items should be checked as described above This message could indicate an issue with the sensor Regardless of the status of each of the gases the instrument can be calibrated by waiting for the readings have stabilized and pressing Start Calibration Timers will begin to count down and when they reach zero the Actual values should be the same as the Target values allowing for slight variations as a result of gas fluctuations Use of a CO Scrubber for Zero Calibratio
7. added as needed Please note that due to the potential for electrical interference it is recommended that communication wires not be run in parallel to AC power wires The right side of the enclosure also contains two Ethernet ports one USB A port and one USB B port These can be used to communicate to the MGA6010 For MGA 6010 Operations Manual Rev Page 5 of 41 detailed information on the use of these ports please see the section of this manual titled Communications Setup Appendix A shows the wiring connections MGA 6010 Operations Manual Rev Page 6 of 41 Recommended Spare Parts PART NUMBER DESCRIPTION 37051 Bowl Filter Element 20264 Ceramic Lined Sample Tubing Assembly with High Temperature Filter 13504 Span Gas Blend 90 cubic feet including cylinder and regulator assembly 13505 Zero Gas Nitrogen 90 cubic feet including cylinder and regulator assembly 32126 Relay SPDT 37198 Sample solenoid Stainless Steel 37199 Calibration gas blocking solenoid Brass 20623 IR Sensor 20624 H2 Sensor 31603 Spud circuit board 31548 Quad 4 20mA analog output circuit board 13550 Color touch screen 312925 Touch Screen Stylus 31135 24VDC power supply 37177 Sample Pump 110VAC 37177 22 Sample Pump 220VAC MGA 6010 Operations Manual Rev Page 7 of 41 Basic Operating Description The Model MGA6010 has been designed for the simultaneous analysis of
8. for the MGA6010 This screen can be accessed from any other screen by pressing the go back or Return button at the bottom right of any screen Depending on the screen it may be necessary to press this button more than once Pump Operation On startup the pump will be off When sampling an endothermic generator or any other gas under positive pressure the pump should remain off For proper operation there should be between 1 0 and 2 0 SCFH of gas flowing through the sensors If the flow meter at the right of the screen or on the inside of the lid does not indicate sufficient flow the pump should be turned on When accessed from the main screen the pump has two possible modes Automatic and Off Pump Control Pump mode O Automatic Return Calibrate flow meter Carbon Calculation The MGA6010 measures the percent carbon in the measured gas by using the percentages of CO 602 and CH in addition to the Furnace Temperature that must be entered by the user It is also possible to determine the percent carbon of the gas as measured by the Oxygen probe by entering the Probe Temperature Probe Millivolts and the Probe CO Factor It is not necessary to enter the information from the probe to determine the percent carbon as measured by the gas analyzer Entering the probe information does allow for a comparison to be made between the percent carbon as measured by the Gas Analyzer and by the Oxygen Probe The MGA6010 will MGA 6
9. gt SuperSystems MGA Operations Manual Please read understand and follow these instructions before operating this equipment Super Systems Inc is not responsible for damages incurred due to a failure to comply with these instructions If at any time there are questions regarding the proper use of this analyzer please contact us at 800 666 4330 for assistance 7205 Edington Drive Cincinnati 45249 513 772 0060 800 666 4330 Fax 513 772 9466 www supersystems com Table of Contents Table Gf Conte tS P 1 aee 3 Mechanical Installation 4 Enclos re g n n uuu Mp Hp Ma iD telis eed M M GI tts 4 Pl mbing 6 secius eee DI pea VER ee qe esI aasan adco UNE ERA aed 4 Wiring Connections 5 Recommended Spare Parts ooo o A e aes Da men ic uae Nuu SG 7 Basic Ope ratins DesciptioM 8 Pump Operation 9 Carbon Calculation E R E ataqu hasa 9 ce 10 CHAT SUD MEGA cons 12 hu ME P M 14 16 Pump Controle sentes Uns e maa ua sas scaled each mua 2 18 Sens r an man aa na nde a ad 19 Performing a Z ro Calibration RUSSIAE 20 Use of a CO Scrubber for Zero Calibrations
10. lines on the trend chart to display If the checkbox next to each trend line is checked then that trend line will be displayed MGA 6010 Operations Manual Rev Page 10 of 41 3 The Datagrid View button will display a screen with the trend data in a grid format instead of with trend lines The trend data is shown in 1 minute intervals Clicking on the OK button on this screen will close the screen down and return to the Chart Display screen The Refresh button 2 will refresh the screen s trend data if the screen is not in real time mode 9 The left green arrow button will move the chart s view backward in time by the specified chart interval The chart interval button will determine the number of hours displayed on the trend chart The options are 1 Hour 2 Hours 4 Hours 8 Hours 12 Hours or 24 Hours o The right green arrow button will move the chart s view forward in time by the specified chart interval The blue arrow button n will toggle real time mode on and off When in real time mode the chart will automatically be updated once a minute MGA 6010 Operations Manual Rev Page 11 of 41 Chart Sub Menu There is a sub menu available by putting a finger or a stylus anywhere on the chart and holding it there for a couple of seconds The sub menu will have the following options available Zoom Restore Add Note Data and Exit IR C 2 2 00 C 1 60 C
11. on the menu list touch the item to highlight it and then press Detail A specific description of each item on the list follows MGA 6010 Operations Manual Rev Page 15 of 41 Sessions The instrument is Logging data any time that it is powered on This data can be viewed by entering the date and time of the data of interest Identifying a sessions through the use of custom identifiers allows for a more user friendly method of viewing and recalling data by allowing the user to apply tags to sections of data These tags can include the name of the operator and the name of the equipment that is being measured The instrument has default values for each of these variables but it is highly recommended that the selections be modified to reflect conditions at the specific facility where it will be used This will allow for the data to be tagged in a way that is easily recognized by any member of your organization For more information on how to set up these selections with custom entries see the Tools Database Management section of this manual Operator Name Operator Equipment Name vq Using the pull down menus select the User Name and Equipment Name from the list of available selections Then begin the session by pressing Start After confirming that you would like to begin a session you will see a sessions summary screen To end the session press the red End button MGA 6010 Operations Manual Rev Page 16 of 41
12. pressure sensor calibration will be complete Thermister Calibration This will be set at the factory and should not need to be adjusted by the end user It allows for the sample gas temperature and the ambient temperature inside the instrument to be set This should only be performed after the instrument has been powered on long enough for it to achieve temperature equilibrium SuperCalc SuperCalc is a proprietary software tool developed by SSI to allow the user to perform different scenarios and view the resulting percent carbon It allows the user to enter gas percentages probe information and temperatures to see the effects of each variable on the calculated percent carbon The data on this screen is independent of any values that are determined by the MGA6010 and it is only provided as a reference tool User Manual An electronic version of the User Manual is located within the instrument for ease of reference Set User Cal Load User Cal This feature allows the user to create new factory default calibration settings for the sensor Instead of reverting to the factory calibration values it can revert back to different calibration settings This is accomplished by first setting the user calibration values At any time after they are set they can be restored by selecting Load User Cal MGA 6010 Operations Manual Rev Page 34 of 41 Shut Down User Interface Detail Return The Shutdown selection will display a sc
13. the enclosure to reduce the amount of radiant heat that the MGA is exposed to In most cases this will not be necessary The mounting and overall dimensions for the enclosure are shown below 22 870 I 11 000 00 375 21 500 20 500 The enclosure is heavily vented to prevent the buildup of potentially harmful gases in the unlikely event of an internal leak This venting will also reduce the internal temperature by allowing the free flow of ambient air around the internal components Plumbing Connections There are five plumbing connections on the MGA 6010 e Sample Inlet The incoming gas to be sampled should be routed through this port after passing through the included bowl filter MGA 6010 Operations Manual Rev Page 4 of 41 e Sample Vent After sampling the gas will exit the enclosure through this port Due to the potentially harmful nature of the gas being measured the gas should be vented to a place in accordance with local regulations and safety standards e Zero and Span Calibration Gas Inlets These are 4 female ports for connecting to calibration gases For more information on acceptable calibration gases see the Calibration section of this manual The incoming pressure of the gas will need to be adj
14. 010 Operations Manual Rev Page 9 of 41 then be able to suggest a change to the probe CO Factor or Process Factor depending on the manufacturer that will allow the probe to measure the same carbon level as the gas analyzer 40221 455448912 DER Carbon Calculation 1701 F Probe Temperature 1698 F 21 88 Probe Millivolts 1072 mV Measured CO2 0 737 C probe 0 28 Measured CH4 8 55 Probe CO Factor C gas analyzer 0 27 Suggested CO SESSION IN PROGRESS COMMS N A 02 Pump Off 16 2 INTERNAL TEMP 84 F COF PF ADJUST N A Change Adjustment Factor Chart Return Measurement of the percent carbon using infra red analysis is generally considered to be a superior method to determining the percent carbon when compared to an Oxygen Probe alone This is because the Oxygen Probe is measuring the amount of Oxygen in the gas and then inferring the percent carbon by assuming a theoretical mixture of endothermic gas Instead of inferring this mixture the gas analyzer will measure the exact composition of the gas to determine the percent carbon Chart The Chart Display shows between 1 hour and 24 hours of process variable data on the screen and can be scrolled back to view all of the data stored on the hard drive The vertical timelines change as the time changes on the screen The function buttons run along the bottom of the screen The Trend Lines button will allow the user to select de select the trend
15. IIXDN SVD NOILVMEITWO DM3Z EGE NO LIVANDI OL D N 296 89 19V1ND2 N 956 12V1ND2 OL v2 OL Wd 19 80 1102 82 01 Page 39 of 41 6010 Operations Manual Rev Appendix B Plumbing Connections WNOILdO 192902 MOSN3S ZH Hk WN LLd yong 1132 N39AXD 1N3A 3 dNVS LN3A 3395130 8100 Wd 96 60 5 1 3993130 VIG 6000 GION3 IDS sav 99 lt gt NoiLvaaravo VIG 0200 GION3 IOS xnv svo mE NDILV3EITV2 PK 1 359130 VIG 6000 GCIDN3 IDS 239 svo HOK 1 0832 8317114 GIDN371DS 3 13 NI 3 dWvS Pd k CW aTdnvS Page 40 of 41 6010 Operations Manual Rev
16. The amount of flow from the gas cylinder should be approximately 1 5 SCFH at no pressure The gas cylinders will be under high pressure so it is recommended that a two stage regulator with a low pressure secondary stage should be used It is good practice to begin the flow of gas before attaching the calibration gas to the instrument This will prevent any high pressure bursts from entering the instrument Calibration gases can be obtained from Super Systems however they can also be obtained from any supplier of custom gases When connecting gases to the automatic calibration ports two MGA 6010 Operations Manual Rev Page 19 of 41 stage regulators should be used and the line pressure should be controlled at approximately 15psi The flow rate of the calibration gas should be adjusted so the flow rate of the calibration gas matches the flow rate of the sample gas during normal operation Increasing the pressure will increase the flow rate while decreasing the pressure will decrease the flow rate Adjustments should be made while the gas is flowing Performing a Zero Calibration On the Sensor Calibration screen be sure that the button at the upper right of the instrument is selecting Zero Calibration and not Span Calibration When this is selected the target values will automatically go to zero Begin the flow of gas at the appropriate rate and allow the readings to come to equilibrium This occurs when the actual values are not moving in
17. ame as if the user pressed the Datagrid View button from the chart screen Exit will close out the sub menu without selecting an item Pressing the red X in the top right hand corner of the screen will take the user back to the status screen MGA 6010 Operations Manual Rev Page 13 of 41 MenuLists Accessing the menu screen will show four available options 9 9 2011 3 08 23 PM Carbon Calculation Sessions Instrument Information Shut down interface Detail Return Carbon Calculation Sessions Instrument Information and Shut Down Interface can be accessed by any users Additional menu items are available when an authorized user logs in using an appropriate Pass Code When the Supervisor Pass Code is entered default 1 the user will also be able to access the Pump Control screen Carbon Calculation Sessions Pump Control Instrument Information Shut down interface Detail Return MGA 6010 Operations Manual Rev Page 14 of 41 To see the full range of options available the user must use the Configuration Pass Code Default 2 This provides the user with all available options including calibration and setup functions 9 9 2011 2 00 46 PM Carbon Calculation Sessions Pump Control Sensor Calibration Automatic Sampling Parameters Communications Setup Instrument Setup Auto Calibration Setup Gas Alarm Setup Instrument Information Detail Return To access any items
18. an be disregarded if the COF PF Adjustment Mode is set to Monitor These parameters only apply when the instrument is in Control mode MGA 6010 Operations Manual Rev Page 22 of 41 Automatic Sampling Parameters COF PF Adjustment Increment 1 COF PF Adjustment Interval minutes 1 Minimum COF PF Value 130 Maximum COF PF Value 220 COF PF Adjustment Mode Monitor Minimum Temperature for sampling 1490 Minimum Millivolts for sampling 1030 mV Minimum Millivolt condition also stops pump Return COF PF Adjustment Increment When adjustments are made automatically this value indicates the size of the step that is made when the COF PF is changed It is recommended that this number remain low to avoid making sudden changes to the process that could be caused by temporary conditions COF PF Adjustment Interval minutes This indicates the frequency that automatic adjustments are made We recommend making small changes at a frequent interval instead of making large changes at longer intervals This will prevent temporary changes in atmosphere from making dramatic adjustments to the COF PF Minimum COF PF Value As a safeguard the COF PF can be prevented from dropping below a certain point This point is the Minimum COF PF value Maximum COF PF Value The Maximum COF PF can also be entered as a safeguard COF PF Adjustment Mode This selection determines if changes to the COF PF should be made aut
19. ation is relatively stable it can be used to perform a span calibration on the sensor There is no drift at the low range of the sensor so there is no Zero Calibration function for the Oxygen sensor There is only a Span Calibration To perform a Span calibration press the Calibrate O2 button on the Sensor Calibration screen Bring the instrument to an office or outdoors where it will be in fresh air When the Oxygen Calibration screen is entered the pump automatically turns on When the Actual value stabilizes press the Start Calibration button This will make the Actual value match the target value GE 40221 5292825694 Oxygen Sensor Calibration Span Calibratio Gas Target Oxygen PEVA 17 7 Last Oxygen calibration 1 1 1980 10 days 20 hours 12 minutes Span calibration to be performed with fresh ambient air using the pump Start Calibration Cancel Automatic Sampling Parameters This instrument is capable of communicating directly with a control instrument This is valuable because it will provide real time entry of the temperature and millivolt information from the probe which will allow for an accurate comparison between the IR Carbon and the Probe Carbon To establish this communications link see Communications Setup Set RS485 Communications The Automatic Sampling Parameters screen will allow the user to adjust the way that the MGA updates the COF PF in the atmosphere controller All of the parameters on this page c
20. calibrations that have been performed since then These dates and times are automatically computed and cannot be manually entered Power Status This screen will identify the amount of voltage that is available to the instrument and also indicate if the instrument is being charged or not When plugged in the Internal Supply Voltage will show the amount of power coming from the internal power supply When unplugged the Internal Supply Voltage will indicate the battery voltage MGA 6010 Operations Manual Rev Page 32 of 41 Tools Database Maintenance Pressure Sensor Calibration Thermistor Calibration SuperCalc User Manual Set User Cal Load User Cal Return Database Maintenance To make the information recorded during a Session more valuable the Sessions database should be populated with relevant information regarding the people who will be using the instrument and the equipment that they will be working on Taking the time to enter this information will provide additional fields to sort by after the data has been collected in a session Maintain Equipment Types Many of the common types of heat treating equipment have been added into the MGA6010 as default entries In the event that some of these items are not relevant or if there are additional pieces of equipment that you would like to add to this list this can be accomplished on this screen Maintain Equipment Each organization has different names for the variou
21. d without significant testing or consultation from Super Systems Inc IR Shim Factor Changing the IR Shim Factor is a way of modifying the computed percent carbon The nominal value is 180 There is an inverse relationship between the IR Shim Factor and computed percent carbon To increase the computed percent carbon this number should be lowered and to decrease the computed percent carbon it should be increased CH Factor This factor increases or decreases the significance of CH in the calculation of carbon CH does not have a significant impact on the computed percent carbon so it has a minor role in the equation If the measured gas has over 5 CH it s role in the equation becomes greater than it should be In these cases the CH factor should be reduced In cases where the CH is present in excess of 7 or 896 this factor can be reduced to zero General Setup This screen shows the current time and date for the instrument as well as the temperature scale The temperature mode can be changed from this screen but the time cannot be changed unless the MGA software is closed Once the MGA software has been closed double click the time in the Lower right corner of the screen and make the necessary modifications Turning the power off and then on again will re boot the MGA software with the updated time Security Settings This page is used to change the pass code used for logging into the menu list The default setting for the Supervis
22. down list MGA 6010 Operations Manual Rev Page 29 of 41 Auto Calibration Setup Auto Calibration Setup Auto Calibration Calibration Purge sec Zero Interval hours Calibration Interval hours Zero Calibration Span Calibration Zero and Span Return The automatic calibration feature allows the instrument to calibrate itself using external supplies of zero and span calibration gases at pre determined intervals or events as dictated by the user The first step when setting up the automatic calibration feature on the MGA6010 is to connect the Zero and Span calibration gases to the appropriate ports on the left side of the enclosure There are blocking solenoids at each of these ports to only allow the flow of gas when it is called for and to prevent the flow when not needed The pressure in the gas lines will need to be adjusted to maintain a flow rate similar to the sample flow rate which should be between 20 and 50psi Method 1 Automatic calibrations based on timed intervals The interval between calibrations is determined on the Auto Calibration Setup screen Auto Calibration must be set to On The calibration purge timer allows for the flow of calibration gas to purge the sample gas from the instrument before performing a calibration If the sample lines are long the time can be increased from the default value of 90 seconds The zero and span intervals are measured in hours The appropriate i
23. e 33 34 Thermister Calibration L IS ertet ero ri eiie ett dene sov lal 34 34 0 User Manuali ehem editt BONIS daly 34 set User Cals Load User Cal 34 Shut Down User Interface m musu haumanii gute en 35 MGA 6010 Operations Manual Rev Page 2 of 41 The MGA6010 is a Non Dispersive Infra Red NDIR gas analyzer designed for continuous operation Unpacking The following items should be included in the box 1JMGA6010 Gas Analyzer 1 Bowl Filter Assembly attach to Sample Inlet port 1 4 Male to 3 16 barb fitting attach to Aux Cal Gas Inlet if desired 1JOperations Manual 1 XGA Viewer CD 2 Male NPT to calibration gas inlet hose fitting attach to Zero and Span Cal Gas Inlet if desired If any of these items is missing or damaged please contact Super Systems Inc at 800 666 4330 MGA 6010 Operations Manual Rev Page 3 of 41 Mechanical Installation Enclosure Mounting It is recommended that the MGA6010 be mounted as close to the sampling point as possible since that will reduce the length of the plumbing lines that will need to be maintained It is intended for use in a heat treating environment but care should be taken not to mount it too close to a furnace or other heat source The operating temperature of the enclosure should be maintained below 122 F 50 C If necessary a heat shield can be mounted behind
24. lly generated and cannot be adjusted by the operator Furnace Temp Source Instrument This line displays the status of communications with the Temperature Millivolt instrument The message is automatically generated and cannot be adjusted by the operator Port Setup This page is used to set the parameters for the communications ports The factory default settings are shown below and they should not need to be changed by the operator MGA 6010 Operations Manual Rev Page 26 of 41 Communications Setup Port Setup Host Address 1 RS232 Port A Baud Rate 19200 RS232 Port A Mode Modbus Master RS485 Port C Baud Rate 19200 RS485 Port C Mode Modbus RS485 Port D Baud Rate 19200 RS485 Port D Mode Modbus Master Instrument Setup The items shown in this menu list are settings that should only need to be changed once Any modifications to the default values will be saved in the instrument Instrument Setup Calculation Factors General Setup Security Settings Factory Default Settings Other Settings Language Setup Detail Return MGA 6010 Operations Manual Rev Page 27 of 41 Calculation Factors There are two items that will influence the calculation of carbon the IR Shim Factor and the CH Factor These values should only be changed after determining that additional adjustments are required based on the specific conditions and equipment at your facility Neither of these items should be modifie
25. nabled on the MGA unless a special request was made to do so at the time of ordering To modify a parameter select the item and press Edit A screen will appear allow for the entry of the limits and the action When any parameter is in an alarm state a notification banner will show at the top of the screen identifying the alarm and the red light on the door will illuminate If desired one of the two MGA 6010 Operations Manual Rev Page 31 of 41 relays or both simultaneously can be energized There are four possible actions for the alarms e None On screen notification of alarm condition No relay actions e AL1 On screen notification of alarm condition plus energizing of alarm relay H1 e AL2 On screen notification of alarm condition plus energizing of alarm relay 2 e AL1 amp 2 On screen notification of alarm condition plus energizing of alarm relays 1 and 2 The relays provide a contact that can be connected to external lights horns or other devices as desired The rating for these relay contacts is maximum of 6 Amps 250 Volts Instrument Information These items cannot be modified they can only be viewed General Information This is information on the revision levels of various components of the instrument This can be valuable when consulting with the factory about issues with the instrument Calibration Dates This area describes the last time the instrument was calibrated at the factory plus any
26. ns If an appropriate Zero calibration gas is not available the included CO Scrubber can be used Using the CO scrubber involves removing the protective caps from the scrubber and attaching it to the inlet hose on the MGA The pump should then be turned on This will pull ambient air through the scrubber and into the analyzer The scrubber is designed to remove CO from ambient air Since ambient air should not have any significant amount of CO or CH but it does have some CO in it using the scrubber will result in the instrument measuring a gas with no CO 602 or CH which is the function of a good zero gas Unfortunately depending on the environment where the calibration is being performed ambient air may contain trace amounts of CO and or CH Also the scrubber uses an expendable media that loses its effectiveness after repeated uses For these reasons Super Systems Inc recommends the use of Nitrogen or Argon instead of the scrubber whenever possible Always replace the caps on the CO scrubber after use If it is left exposed to ambient air the media will lose it s effectiveness The amount of time that the Scrubber is exposed to ambient air is directly related to it s effective life span If the protective caps are replaced after each use the scrubber will provide years of service MGA 6010 Operations Manual Rev Page 20 of 41 Never mistake the scrubber for a particulate filter Not only is it not designed for this purpose but
27. nterval can be based on the process and the desired degree of accuracy The standard values are 48 hours for a zero calibration and 96 hours for a span calibration MGA 6010 Operations Manual Rev Page 30 of 41 Method 2 Automatic calibration based digital inputs It is also possible to initiate calibrations externally This method may be beneficial if the calibration is to be tied in with a process event or as directed by a PLC Connecting Terminals 2351 and the adjacent GND terminal will initiate an automatic Zero calibration Connecting Terminals 2331 and the adjacent GND terminal will initiate an automatic Span calibration Calibration can be initiated using the digital inputs regardless of the timed interval calibration setup There are no setups required for the digital inputs since they are not user configurable The three buttons at the bottom of the screen Zero Calibration Span Calibration Zero and Span Calibration can be used to initiate immediate calibrations from the Auto Calibration Setup screen These buttons will not work unless the automatic calibration feature has been enabled Gas Alarm Setup Gas Alarm Setup Parameter Lower Limit Upper Limit none none none none none none none none none none none none none none none none none none Return The MGA 6010 allows the user to configure various alarms For each parameter the Lower Limit Upper Limit and Action As default no alarms are e
28. omatically or if the instrument should only monitor the conditions and not make any changes When in Monitor mode a COF PF will continue to be suggested but no modifications will be made to the atmosphere controller MGA 6010 Operations Manual Rev Page 23 of 41 Communications Setup This screen allows the user to view and modify the method of communications between the instrument and external devices Communications Setup IP Address Set RS485 Communications Port Setup Detail Return IP Address This section identifies the IP Address of the instrument When connected to a network the MGA screen will obtain it s own IP Address It does this during the power up procedure so if you are going to communicate via Ethernet plug the cable into the instrument before turning it on MGA 6010 Operations Manual Rev Page 24 of 41 Set RS485 Communications RS485 communications can be set up to automatically enter and update data from the oxygen probe and if desired make modifications to the COF PF in the atmosphere controller Communications Setup Set 45485 Communications Port Usage Modbus Master Port Baud Rate 19200 Probe Temp mV Instrument SSI AC20 Probe Temp mV Instrument Address 0 Status Not configured Furnace Temp Instrument SSI Furnace Temp Instrument Address 0 Status Not configured Return Port Usage This is the communication method used to supply information to the instrument
29. or Pass Code is 1 and the default setting for Configuration is 2 The maximum value for either code is 32767 The Configuration Code will also work for all items on the Supervisor Pass Code items so entering the Configuration Code default 22 will give you access to all available menus Factory Default Settings Selecting this option will cause the instrument to revert back to the settings that it contained when it came from the factory Any changes or modifications made since then will be lost Other Settings This screen allows the display of the calculated dew point This value is not normally displayed because it is only accurate during certain conditions Calculating dew point by using the gas values requires assumptions to be made regarding the composition of the gas being sampled and since these assumptions are not always accurate the resulting dew point is not always accurate When using Endothermic gas in a heat treating environment the calculated dew point will usually be close to the correct value but there is no substitute for a dew point that is determined through direct measurement of the moisture content of the gas When the dew point is enabled it will appear near the bottom left of the Carbon Calculation screen MGA 6010 Operations Manual Rev Page 28 of 41 Language Setup The instrument language should be pre configured at the factory prior to shipment but they can also be changed by making a selection from the drop
30. reen asking whether or not you wish to shutdown the interface with the MGA MGA 6010 Operations Manual Rev Page 35 of 41 Appendix A Electrical Drawings 390748 1 1 SALONA wf Wd 06705 Page 36 of 41 MGA 6010 Operations Manual Rev TU ZERO CALIBRATION GAS TO CALIBRATION v SOL TU SPAN CALIBRATION GAS LACS MGA 6010 Operations Manual Rev MALE CONN MATING SIDE SEE DETAIL THIS SHT TO COM2 RS232 CUWIN3200A TOUCH SCREEN OPERATOR INTERFACE IP N 13550 Page 37 of 41 296 89 nv Land NOILVBEIOWO aw SVO Ds3Z ESE w2 SW SVD NOLLVYAI WO NvdS 8D1V3I0NI anv 4 NOILVMEITNO AMIVIIXDN SOLVSIGNT Cas TANS SVD SS3OUNd SOLVSIGNT aw Sv NOI 41 1 MAZ Ss SVI NDI1VBEITW2 NvdS D1V3I0NI IN NV 10017 DIVJINI 313 55 A3IA 3 murum 3SV29 40 1 3WW34 N3 73 815 1 We 50 90 1102 82 01 8 8 158 Page 38 of 41 6010 Operations Manual Rev JAWA 21042705 js A NS SvO 5532034 IDN3 DS SW SVD NOILVNEITNO NVdS JAWA IDN3 TDS OW 1504 NOILVMEITNO ANIV
31. s pieces of equipment in their shop Those names should be entered here Each name needs to be associated with a specific Equipment Type so that database should be populated first Maintain Sessions The MGA6010 is designed to delete the oldest files first in the event that the storage capacity has been exceeded It is also possible to delete old files manually by entering a date on this screen All files that were made before that date would be permanently deleted It is important to note that after the data has been downloaded to a computer a copy is stored on that computer The data will always be available on the computer even if it has been deleted from the screen MGA 6010 Operations Manual Rev Page 33 of 41 Maintain Users The names of all potential users can be entered here Names can be added and deleted as required Compact Database Periodic database compaction will help make data storage more efficient and allow more data to be stored before it is automatically deleted Nothing is deleted or lost when this button is pressed and the only result will be a performance improvement Pressure Sensor Calibration The pressure it set at the factory for local conditions For optimal performance the ambient pressure should be reset at the final destination This can be done by determining the barometric pressure and the elevation and entering them on this screen After the two values have been entered press the Calibrate button and the
32. since it removes the CO from the gas it will result in very inaccurate readings For these reasons it should never be used during a Span calibration Performing a Span Calibration A Span calibration is performed the same way as the zero calibration with two small changes First the selector button at the top should be on Span Calibration instead of Zero Calibration Second the gas values for the specific cylinder of gas that is being used need to be entered into the Target values This is done by pressing the blue box associated with each gas and entering the value as it is shown on the cylinder For example the nominal value for CO may be 2095 but your cylinder may actually have 19 967 CO This is the value that should be entered as a target After the gas values have been entered proceed with the calibration in the same manner as with the zero calibration MGA 6010 Operations Manual Rev Page 21 of 41 Calibrating the Oxygen Sensor The MGA6010 uses an electrochemical Oxygen sensor that should last approximately two years depending on usage It measures oxygen to a resolution of 0 196 so it is not suitable for measuring trace amounts of Oxygen Its intended use is for troubleshooting problems such as air and or water leaks The information from this sensor is not used in the calculation of percent carbon Calibration of the Oxygen sensor does not require a special calibration gas Ambient air contains 20 9 02 and since that concentr
33. sor Calibration Sensor Calibration O Span Calibration Verify Span Gas Target Actual Status CO 0 01 OK CO2 0 053 OK CH4 0 15 OK Last Zero Calibration 5 3 2011 8 days 20 hours 32 minutes Last Span Calibration 5 3 2011 8 days 20 hours 22 minutes Pump should be off when using pressurized cylinders of gas Calibrate 2 Cancel Pump Start Calibration Two types of calibrations can be performed on the NDIR sensor Zero and Span The Zero calibration should be performed with a gas that has none of the measured gases in it Ideally this would be pure Nitrogen or Argon The concentration of the Span calibration gas should closely resemble the gas that is being measured For a heat treating application measuring endothermic gas the ideal composition would be CO 20 CO 0 5 CH 5 0 Hz 40 N Balance Since the accuracy of the calibration gas directly influences the resulting accuracy of the instrument the highest possible accuracy grade should be obtained Some gas suppliers refer to this as a Certified Primary Standard The high degree of accuracy is not required to obtain nominal values that exactly match the values shown above The accuracy is required to know the exact composition of the gas in the cylinder The actual composition will be shown on the bottle when it is delivered When flowing calibration gas into the analyzer the pump should be off
34. usted to allow the flow to be the same for the calibration gas and the sample gas flow rate The incoming pressurized gas goes through a small fixed orifice inside the analyzer which should require between 20 and 50 psi to maintain proper flow These ports are used with the automatic calibration system to provide calibrations at predetermined intervals or events The use of these ports is not required for the operation of the MGA6010 e Auxiliary Calibration Gas Inlet This NPT female port provides another entry point for both zero and span calibration gases If calibrations are being performed manually this port should be used for both gases The flow of gas through the MGA6010 is controlled by solenoid valves Each valve is normally closed and for safety purposes all valves will shut to prevent unwanted furnace gases from entering the instrument when power to the enclosure is lost or the specified sampling parameters are not met Appendix B shows the plumbing connections Wiring Connections Terminal blocks inside the instrument are available for the following purposes Incoming line voltage 110 220 VAC RS485 Communications 4 20mA Outputs Alarms Digital Inputs Each terminal block is numbered according to the included electrical drawing Knockout holes in the enclosure have been provided to simplify wiring connections Knockouts are located on the right side and bottom of the enclosure Additional or alternate locations can be
Download Pdf Manuals
Related Search