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FGA 300V(X) Vertical Flue Gas Analyzer User`s Manual

1. dolo Figure 25 Display Electronics Console Circuit Board Top View Model FGA 300V X Vertical Gas Analyzer User s Manual 49 Chapter 4 Calibration 4 4 2 Zero Check The oxygen span gas which consists of 5 O and 95 N 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 To perform a zero check complete the following steps 1 Introduce the zero combustibles gas into the calibration gas inlet port on the Main Analyzer Unit Note See Figure 23 on page 44 for the location of the calibration gas port and refer to Regulating the Calibration Gas Flow Rate on page 43 for the correct flow rat
2. Figure 63 FTC Circuit Board Previous Drawing 1703 929 Model FGA 300V X Vertical Gas Analyzer User s Manual 149 Appendix F Previous Configurations NOILVYAdO A 022 SMOHS DILVWJHOS 7 038 Nad 2 038 T Nag AOZT AOZT a dW31 ASVIYINI OLMO 1snfQv dW3L 626 2071 213 Q8 V2 YATIOYLNOD OY OO PF iO iO X rn G c A Occ Alddn s 6 1o uuoo 8 L 82 T JINYOISNVIL EM ZM 6 8 1732 EST 913 dINYOISNVIL SANIT dd ONISIM S3IHOJSNVS L NOIL2313S JOVLION Sy3lV3H LVLSOWdSHL o a diN31 J9VN3NY C o e ud YOSNAS N39AXO 4JO123 YOSNAS J84NLVIIANIL SJOVNYNS JALOV OY OO OINA XE rn CN e OY OO r O n X IO CN eH JOSN3S 338 e a
3. V a OQO neos 2H OD OD SLNdNI SLAdLNO Tal eal MAIA 3GIS 6911 262 BEL TOER MaIA SV3S8 asny 19 U S UIOW 331 Bench Mount Figure 52 300D Display Model FGA 300V X Vertical Gas Analyzer User s Manual 126 Appendix B Outline and Mounting Dimensions say3u1 s1938U11 UU ur 91D suorsueuuiq p i ddns p109 eur qpuop1 d W9 T qi 9 64 5 72 1uBI A cal TAE CU Ue Pe me We AR 8 chy a ON 2 ONN 2 ON O 8WO2 20 gWOd S1ndino SAV 138 lt al sal AMIA dvd 556 LEZ MalA 3015
4. E 3 Standard Weatherproof Model Explosion Proof Flameproof Model Figure 17 Main Analyzer Unit Top View TB1 Location Model FGA 300V X Vertical Gas Analyzer User s Manual 25 Chapter 2 Installation 2 6 4a Connecting the Analyzer to the Remote FTC Box cont 2258 slo eossesssss_e y BOER SEE 4 49880009006 SA S522 els sozzanacaa 0 El FTC Board Standard Weatherproof Model e eesessessss_s 8 EJ E E C ET EIE E 8 S i 5500020000 e aa Oa Explosion Proof Flameproof Model Figure 18 Remote FTC Box Top View TB1 Location Protective Conductor Terminal 26 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 6 40 Connecting the Display Make wiring connections from terminal block TB1 in the 300D Display Console to terminal block TB1 in t
5. Figure 45 Combustibles Adjustment Components 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 300V X Vertical Gas Analyzer User s Manual 117 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 45 on page 117 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 Adjust potentiometer R111 for a zero value as read on the front panel display 4 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 5 Adjust potentiometer R111 for the desired full scale value as read on the front panel display 6 Adjust potentiometer R129 until the analog output corresponds to the value on the front panel display 7 Remove the resistors from TB1 and the jumper from W103 118 Model FGA 300V x Vertical Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions Appendix B Outline and Mounting Dimensions Model FGA 3
6. E PLIS H I i u lt L oms FTC Board u ooo eco mm Standard Weatherproof Remote FTC Box cm ua SEEGER e ppm Ela El FTC Board us 90 898868058808 TB3 TB2 RELAYS OUTPUTS COMB 02 COMB O2 NO C NONO C NC E x 6 5 4 3 2 1 4 3 2 iS Le Explosion Proof Flameproof Remote FTC Box Figure 19 Standard Display Console and Remote FTC Terminal Block Locations Protective Conductor Terminal 28 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation FIOSNOD SOINO3
7. UT 62 84 661 Proof Flameproof Explosion Figure 50 Remote FTC Box Model FGA 300V X Vertical Gas Analyzer User s Manual 124 Appendix B Outline and Mounting Dimensions seuoul siajau1 uu Ul BJD SUOISUBWUIG paljddns pio2 u 1 ajqoyonjeq W9 T ql 2 64 2 1Ublam AN3IA LNOS3 I 81 S97 Jez jeuy ses n d 00 seues 2H OD eal lejlg v cO 8WO5 SLNdLAO cal MIA 3015 A 6911 62 61 5 287 MIA 4V38 T6 2 eese A 18 TT 00g 19 U SUIDA 23l Rack Mount Figure 51 300D Display 125 Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions SYD sje1euur iu ui BID SUOISUBWUIG pei ddns p109 aun qouop1 q W9T gj S S 64 72 1yblam r 680 ST MalA LNOYS
8. 1 lul SUIDN 931 9 ILE 6 0 18111008 LNOLND 13NVd ld 920 90 E P 486 72 9 6 872 MIA LNOYS ld 920 S 9 DD HUM Seo eny Aw 40 cH OD P 6 01 792 7 127 Panel Mount isplay 300D D 53 igure F Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions seopid ty SINC A90UN 6 70 02G JO 86 0 S29 seopjd z puJaju PNIS uonpuruue pjetus SW T 31v5S 3015 35943138 31V 1d NOLLVOIHILN3Q say3u sJe3euuijiuu ur eo suoisu uuiq dI 6 1 64 9 1yblam eunso pu3 paunJe 99d vy2 e9 4 172129 et vv e 29 r s91 2b 00 sanas LL ood J z jeuy seg anja E LO T o seop d y TE0 80 664 02 PE gt I 0T 292 gt 1801 942 gt T SOT L Standard Weatherproof Figure 54 300D Display Model FGA 300V X Vertical Gas Analyzer User s Manual 128 Appendix B Outline and Mountin
9. UE LINA AWIASIO 1V LIOSIG NOD LAdNI ONIdIM X09 YSTIONLNOD dW3L JOVNY NJ e a S318l1Sn18A02 ONISIM XOd AYOSSIDIV 517 Rev E 1442 ing Previous Draw Diagram iring W 64 Figure Model FGA 300V X Vertical Gas Analyzer User s Manual 150 Appendix F Previous Configurations paso A puuJoN woy sejgnsnquo5 UOWWOD ulb v sej qnsnquJio uedo f puuloN uubjv Sajqnsnquio uedo A JOWJON woy ue6 xo UOWLWOD uup y ua Axo paso A puuoN uupb y usb xo 1ndino JU9 IND sejqnsnquuo 1ndino uano s qisnquioo 3ndino abpyon sayqnsnquoD 1ndino aboyo sajqnsnquioD indino Juano uabAKO indino jua un UaBAXO indino e8D3 oA uabAxO 3ndino apoyo ue6 xo annoy se qnsnquio annoy se qnsnquio5 aduaajay se qnsnquio e2ueJejey se qnsnquio Josues UIBAXO Josuas USBAXO uondu seg Tal Tv ev Ty ed TO O leqp1 N ee msi ono navn st in o s so m o Uld d ele vw Cy e ZOTM ele OTM L Oo sis Ne XS alll NG C cu al II 000 A Ez 000 BNI TS eee jim N Avidsid SONV wavy eS ES YS 3 92 punoJo DAN N aun 1 uonduoseg equ uld cal 1703 001 ing it Board Previous Drawi Ircu isplay Ci D 65 Figure 151 Model FGA 300V X Vertical Gas Ana
10. Appendix D Wiring Diagrams and Circuit Boards Model FGA 300V X Vertical Gas Analyzer User s Manual Contents vil Contents Appendix E Default Settings eed OSI AAA oR UE LONER Ware aS ATA AA AAA AS AAA AR RIA AA AO NOS 141 E2 EMCCOMPIINCE LL uU L p Qanman diia 141 ES VEC ODAC Circ sana lll cacti 141 Appendix F Previous Configurations El OVERVIEW TT 143 F2 Testing the FTC Board and Tronsformer 143 F3 Replacingthe PIC Board RUSO cui AA 145 Rae Replacing the FIC Bodonal Teide taro Ee bete O da ias 146 ES Replaciigtie TAnSto Mera arar AA es PEE DO AA Ri PAE 147 F6 Adjusting the Sensor Furnace Temperoture 148 FZ Previous Wiring Diagrams and Circuit Boords 148 viii Model FGA 300V x Vertical 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
11. SAV 138 81 1093190 Sse qnsnquuo5 Jopayag se qnsnquJo5 Josues UBBAKO Josuas UahAKO uondisosag 2927 SLAdLNO caL punos9 annoy SAJqnsnquio uouJulo5 SaJqnsnquio soualajay se qnsnquuo5 punou5 pm V 3 y pm Josues ue xo Josues ueb xo punoJo m uonduoseq c s or o 3k Appendix D Wiring Diagrams and Circuit Boards S1fldNI Tal 1303 aun jpinaN uondiJosag ORERE SOTvNV EGG EE is ES e oe o c6 r e SNIVW 1791 1703 011 ing Model FGA 300V X Verti
12. Figure 26 Blinking Flow Diagram 1 Check all wiring including the factory wiring on the terminal blocks in the Main Analyzer Unit remote Furnace Temperature Control FTC Box and Display Console Refer to the wiring instructions in Chapter 2 Installation and the wiring diagram in Figure 59 on page 137 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 27 on page 55 which shows the sample system with the analyzer enclosure removed and short them together with a jumper The oxygen display should read 20 9 or 0 mV by pressing the mV key If the wiring is good and a 20 996 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 54 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 1a Check the Wiring cont Inner Clip Outer Clip Figure 27 Oxygen Sensor Clips 5 2 16 Check the Tempera
13. Figure 40 Convection Loop Clamp Location 9 Use a screwdriver to remove the clamp on top of the sensor furnace DO NOT allow the sensor furnace to fall off the convection loop oxygen sensor assembly as the clamp is being removed see Figure 40 WARNING The sensor furnace may still be hot Always use heat resistant gloves when handling it 10 Lift the convection loop oxygen sensor assembly straight up and out of the sensor furnace This completes the removal of the old sensor furnace Install the new sensor furnace immediately by completing the instructions in the next section Model FGA 300V X Vertical Gas Analyzer User s Manual 89 Chapter 6 Parts Replacement 6 3 66 Installing the New Sensor Furnace 1 Locate the ceramic power block on the top surface of the new sensor furnace 2 Slide the removed convection loop oxygen sensor assembly into the top of the new sensor furnace Position the furnace so that the mounting hole in the top of the furnace lines up with the clamp 3 Secure the convection loop to the top of the sensor furnace with the clamp and screw that were previously removed 4 Position the sensor furnace convection loop assembly over the manifold as shown in Figure 39 on page 88 5 Finger tighten the nut on top of the manifold to the fitting beneath the sensor furnace Also finger tighten the nut on the upper section of the convection loop to the fitting on the lower section of the convection loop see F
14. This completes the replacement of the oxygen sensor clips 78 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 3 Replacing the Oxygen Sensor The oxygen sensor is mounted on top of 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 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 D A 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 Model FGA 300V X Vertical Gas Analyzer User s Manual 79 Chapter 6 Parts Replacement 6 3 3a Removing the Old Oxygen Sensor 1 Remove the main analyzer unit cover as described in the Removing the Cover section on page 76 2 Locate the
15. 300D Digital Display Part Number Description 1703 011 XXX Linear Board refer to Table 20 on page 101 for ordering information 1703 002 02 Display Board Oxygen Channel 1703 002 03 Display Board Combustibles Channel 1703 002 04 Display Board Oxygen Combustibles Channel 1193 504 Fuse 200mA 1193 503 Fuse 100mA for 220VAC units Model FGA 300V X Vertical Gas Analyzer User s Manual 99 Chapter 6 Parts Replacement 6 6 Spare Parts cont Part Number 1214 511 Table 19 Spare Parts List FGA 300V 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 XX Temperature Control Board See Table 21 on page 101 for ordering information 1705 552 03 Furnace Assembly with bracket 1705 5
16. 4 Close the cover on the remote FTC Box and reconnect the main power to the system 5 Refer to Chapter 4 Calibration and recalibrate the oxygen sensor and the combustibles detector This completes the replacement of the FTC board Model FGA 300V X Vertical Gas Analyzer User s Manual 97 Chapter 6 Parts Replacement 6 5 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 5 1 Replacing the 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 300V 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 43 and complete the following steps to replace the display board fuse BEEBE Figure 43
17. Display Board Fuse 1 Disconnect the main power to the FGA 300V 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 5 Close replace the cover on the Display Console 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 98 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 6 Spare Parts 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 in Table 18 and for the FGA 300V X in Table 19 on page 100 To purchase any parts whether listed or not contact the factory for assistance Table 18 Spare Parts List
18. Temperature S Special please specify Control Setting Analog Output Format Temperature must match analyzer 108 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 7 Specifications 7 5 Ordering Information cont The information below shows how the FGA Current Output Board Part Number is configured from the options specified FGACB Table 25 FGA Current Output Board Ordering Information CATEGORY OPTIONS 1 100 VAC 2 110 VAC 3 220 VAC 4 240 VAC Voltage 1 Supplied loose 2 Mounted with furnace temperature control card 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 4 0 20 9 Oxygen 5 0 25 Oxygen S Special 0 None 1 0 1V Output 2 Tropicalized S Special Special Temperature 0 Factory selected option Control Setting Temperature must match analyzer Model FGA 300V X Vertical Gas Analyzer User s Manual 109 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 Temperature Range 1 be
19. 12313 AWIdSIO STIAGOW d8H SISSVHO tr 134905 13NVd 931 OL 0381M AJ019V3 T18L N t81 LAdLNO Teal N39AXO NN IV N39AXO AlddNS SNIVIN SOI L3 VNVd 39 A8 Q3r1ddns LON 1N3W3SINO3S AYVIA 39 GA1 T 0101 931 T OTOT9 N3 HLIM SONVMdWOD Y0W G3YINOIY HOLIMS 123NNOOSIG SNIVIA xog 213 SLOWSY AlddNs SNIVIN XAOQOE LON AINO A00 31ON LINA YIZATUNV NIVIA 29 TT SAN Y31V3H ecl IVILA3N vl 34M 39VN4N3 YOSNAS LAdLNO 8WO2D WV IV 8WOD 7 3J4NLVIIANIL OT 32N383334 401393130 NOWWOD SATVILSNEWOD SINdLNO uvad LV SIVNIWYSL d83 Q00 SAYLNAD UJUJ09X09 S3IH1N3 LdN t XZ S9dl S 91 Dll p X33 NMOHS LON SLAdNI S341N39 WuIZ9 SAINLNA WWOZD xt 99dl diM Goo dX3 000 Ag1N3 WWUZZ XT S9dl ddM 213 A tas 00 SOLOS SI41N3I9D UlUJ 9xg9 SSIYLNA LdN t7 X9 S9dI S 91 911 P X33 3AUDV SAINLNA WW2 2G xe A00 V93 im Sl Seules sezieuy Seo ond SSINLNA LdN Z TX XA O0 V93 h iagram D ion 20 Interconnecti Figure 29 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 6 5 Connecting Recorders The 300D Display Console provides a pair of outputs for connecting a recor
20. 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 84 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 5a Removing the Old Temperature Sensor 1 2 3 4 5 Disconnect the main power to the FGA 300V X Remove the Main Analyzer Unit cover as described in the Removing the Cover section on page 76 Disconnect the temperature sensor leads from pins 3 and 4 on terminal block TB1 in the Main Analyzer Unit Loosen the clamp that holds the temperature sensor to the bottom of the sensor furnace Extract the temperature sensor from the bottom of the sensor furnace See Figure 37 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 Sensor Furnace m w RTD Sensor Clamp Figure 37 Temperature Sensor Location Model FGA 300V X Vertical Gas Analyzer User s Ma
21. 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 70 Model FGA 300V x Vertical 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 Refer to Figure 59 on page 137 and verify that the combustibles detector is correctly wired at terminal blocks TB1 in the Main Analyzer Unit the remote FTC Box and the Display Console Make sure that none of the wires interconnecting the three terminal blocks is loose or broken 2 Inthe Main Analyzer Unit disconnect the common wire from pin 9 of terminal block TBI and attach one lead of a multimeter to the disconnected wire 3 Attach the other lead of the multimeter to pin 10 of terminal block TB1 record the resistance of the reference element and do one of the following Ifthe resistance is 1800 1900 ohms proceed to step 4 Ifthe
22. Enclosure Special Model FGA 300V X Vertical Gas Analyzer User s Manual 107 Chapter 7 Specifications 7 5 Ordering Information cont The information below shows how the FGA 300D Part Number is configured from the options specified B C D E F G H J 300D Table 24 FGA 300D Digital Display Ordering Information CATEGORY OPTIONS 0 No enclosure OEM 1 Weatherproof enclosure IP65 2 Rack mount 3 Bench mount Package 4 Panel mount 7 Flameproof enclosure EEx d IIC T6 8 Flameproof enclosure with FTC EEx d IIC T6 9 304SS Weatherproof enclosure IP65 S Special 1 100 VAC 2 110 120 VAC 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 Zirconia 4 0 25 Oxygen Range 5 0 1000mV Cell mV 6 0 8 1 2 0 8 2 0 Air factor Specify fuel 7 5 10 20 25 Excess fuel and range 8 5 10 20 25 Equivalent combustibles S Special 0 None 1 0 2 000 ppm combustibles Combustibles 2 0 5 000 ppm combustibles Range 3 0 10 000 ppm combustibles CO H2 4 0 2 00 combustibles S Special 0 Single oxygen and single combustibles alarm standard configuration Alarms 1 Dual oxygen alarms 2 Dual combustibles alarms 0 None Special 2 Tropicalized S Special 2 812 C standard for 300V and 300VX
23. 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 lt 25 A A Pf gd Billerica August 2010 Issued Mr Gary Kozinski Certification amp Standards Lead Engineer ex C 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 910 105 Rev F
24. Model FGA 300V X Vertical Gas Analyzer User s Manual 77 Chapter 6 Parts Replacement 6 3 2a Removing the Old Sensor Clips 1 2 3 4 Remove the main analyzer unit cover as described in the Removing the Cover section on page 76 Disconnect the oxygen sensor leads from pins 1 and 2 of terminal block TB1 in the Main Analyzer Unit Locate the oxygen sensor and the oxygen sensor clips see Figure 33 on page 77 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 6 3 2b Installing the New Sensor Clips 1 2 3 4 5 6 7 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 Main Analyzer Unit Install the Main Analyzer Unit cover by completing the steps in the Removing the Cover section on page 76 in reverse order Recalibrate the oxygen sensor as described in Chapter 4 Calibration
25. Note Asa special consideration for certification the flue gas can not generate an explosive atmosphere Sample probe lengths up to 1 5 m Analyzers for sampling at flue gas temperatures up to 1700 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 300V X Vertical Gas Analyzer User s Manual 105 Chapter 7 Specifications 7 5 Ordering Information The information below shows how the FGA 300V Part Number is configured from the options specified FGA300V Table 22 FGA 300V Weatherproof Ordering Information CATEGORY OPTIONS 0 None Oxygen Sensor 1 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 No furnace temperature control card Spares orders only 3 Remote Weatherproof FTC enclosure IP65 5 304 SS remote Weatherproof FTC enclosure IP65 S Special 1 1 1 2 male NPT thread mounting 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 5 Two flanges with gasket ANSI 3 300 Ib C S for mounting 6 ANSI 4 150 Ib flange C
26. 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 GE for assistance Model FGA 300V X Vertical Gas Analyzer User s Manual 111 Appendix A Rotary Switch Settings A 1 Overview cont e 0 00000000 eoeeoeoooooooo se se sz si ALARM ANALOG DISPLAY FUEL CETS IA EY EA TE Fi
27. S mounting 7 Two flanges with gasket ANSI 4 150 lb C S for mounting S Special Furnace Controller Enclosure Mounting 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 812 C Control Setting S Special temperature setting 700 770 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 106 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 7 Specifications 7 5 Ordering Information cont The information below shows how the FGA 300VX Part Number is configured from the options specified B C D E F G H J K FGA300VX Table 23 FGA 300VX Explosion Proof Ordering Information CATEGORY OPTIONS 0 None Oxygen Sensor 1 Standard oxygen sensor type 1 2 Oxygen sensor for stoichiometric co
28. 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 conjunction with switch S2 the analog output range is determined by the S2 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 115 switch S2 3 and switch S3 1 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 115 For other S2 53 combinations refer to Figure 44 on page 112 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 T Switch 52 Position 0 96 oxygen Table 30 Position 1 96 excess Fuel Table 30 Position 2 96 equivalent combustibles Table 30 Position 3 air factor Table 31 Position 4 combustibles index Table 32 Position 5 sensor mV Table 33 114 Model FGA 300V x Vertical Gas Analyzer User s Manual Appendi
29. 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 4 in 10 cm 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 Model FGA 300V X Vertical Gas Analyzer User s Manual 17 Chapter 2 Installation 2 3 2 Preparing the Site cont 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 300V X to ensure a proper match of the mounting components Top View GAS FLOW Dimensions are in inches millimeters Mating Flange da oam 2 Sch 80 Pipe LA LL 50 8 LEE Tf 1 l H Welds 4 1016 Mounting Plate vij min i 1 7 8 47 6 min Masonry Wall 90 Side View Figure 14 Installed Pipe and Mating Flange Although the rotation of the Main Analyzer Unit with respect to the gas flow direction is not critical if the unit is ordered with an installed mounting flange the mating flange orientation shown in Figure 14 will ensure that the analyzer is square to the duct In addition make certain that the mating flan
30. Thermostat BP FTE OCR upa Satu aus erases Mab ITA OS ce SENLA 6 4 1 Replacing the FTC Board Fuse 6 4 2 Replacing the FTC Boord 6 5 Display Electronics Console 6 5 1 Replacing the Display Board Fuse 6 6 Spare PAS at A a 6 7 Ordering OMAN o a e Petal o da Chapter 7 Specifications 7 1 GenerqlSpecificotions 7 2 OVIEN DEC CONS vei RS d ow Ete ASQ RUN HERES 7 3 Combustibles Specifications u valable DEOS ccs coer o es do de as Lo Ordering ATOM As iT os ees t iim by EDI S EU AA AS a Appendix A Rotary Switch Settings AA e a a r ie hs pha dedico p ln A2 Selecting the Display Parameter 5 Selecting the Fuel TUBE tre Cie aed dde isa Ee eee HK bos A 4 Adjusting the Oxygen Channel A 5 Adjusting the Combustibles Channel A 5 1 Setting the Scale Type A 5 2 Setting the Zero and Full Scale Volues Appendix B Outline and Mounting Dimensions Appendix C The Nernst Equation EL OE TE 2 EQUIDAD EAS A Cre Oe YR ES The FGA 300V X Equqtions
31. Voltage Directive 73 23 EEC the standard 300V 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 300VX IMPORTANT These symbols indicate Caution dangerously hot surfaces and risk of electric shock respectively AN AN WARNING Power up the FGA 300V 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 Box WARNING To ensure safe operation of the FGA 300V 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 300V X Vertical Gas Analyzer User s Manual 9 Chapter 2 Installation 2 2 Physical Description 2 2 1 Standard Weatherproof Enclosure The standard weatherproof configuration consists of two se
32. X Vertical Gas Analyzer User s Manual Index D Date of Publication 1 Detector Combustibles 1 8 Disconnect Device 9 21 Display Combustibles 39 On Sch avert tigate ae ete ETES 39 Display Electronics Console Deserpti m EIA eg alo dads Ge Be 5 O tare e e QU ee are pss 66 WIDE qe eU ORENSE Vag ee es 23 27 Display Parameter Selecti0N 113 Document Number 1 E EMC Compliance 141 Enclosures ea a GOO baa en SKY Pa 1 Environmental Compliance iv Error Indicators Combustibles 22 ea ii fete et Seats eid 69 Di A aa eet E WS A 53 Tables AUR eM aus Du a 8 52 F FTC Board REPAMAR 96 146 A Naa uu Ree Weert 61 143 FTC Box Ambient Temperature 22 Description 1 ove PU basa ae beds 4 12 MEE ia sr D bores icd bei erae 22 24 27 Fuel Type Selection 113 Furnace See Sensor Furnace Fuse Display Board Replacing 98 FTC Board Replacing 95 145 G Gas Fla as 14 H Heaters Replacing 91 153 Index l Information Paragraphs 11 K Keyp dia asa tad Mos alo a tg loa da 39 L LVD Compliance 5 22x P vn 9 21 141 M Main Analyzer Unit DESCADION curiosas x mee Yos Nae d A GEAR 10 MOI a A A LE ALD e ME 21 Removing Covet civic
33. 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 procedures 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 45 on page 117 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 45 on page 117 A 5 20 ALinear Scale To set the zero and full scale values for a linear scale complete the following steps see Figure 45 on page 117 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
34. activated which produces a 1 0 reading on the combustibles display To correct this error refer to the flow diagram in Figure 26 on page 54 and perform the following checks in the order given 5 21a 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 AN A Model FGA 300V X Vertical Gas Analyzer User s Manual 53 Chapter 5 Troubleshooting 5 2 1a Check the Wiring cont BLINKING open circuit error E1 Check TB Wiring Check Sensor Wiring 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 Line Voltage No Voltage OL Reading Replace Furnace Defective Display Unit Check FTC VAC In Line Voltage Check FTC Fuse Fuse Good Replace FTC Board No Voltage Fix Main Power
35. 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 either 770 C 1 418 F or 812 C 1 494 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 equivalent combustibles in the flue gas Note A sensor furnace temperature of either 770 C 1 418 F or 812 C 1 494 F is standard for the FGA 300V X Consult with a GE engineer to determine which temperature is best suited to your situation 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 th
36. at 770 C Model FGA 300V X Vertical Gas Analyzer User s Manual 133 Appendix C The Nernst Equation 0 0001 Oxygen Concentration Figure 57 Oxygen Sensor Output at 812 C 134 Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix D Wiring Diagrams and Circuit Boards Appendix D Wiring Diagrams and Circuit Boards Model FGA 300V X Vertical Gas Analyzer User s Manual 135 Appendix D Wiring Diagrams and Circuit Boards ANNOY9 J9VNINY J9VN3NY Walns 5 Pin Connector plugs into TB1 3NI 2A SLOBLOW F1 703 1271 gasn 10 a3sn 10 gasn 10 gasn 10 3SN 10 3SN 10 9 Pin Connector plugs into TB2 21 018 91 018 Figure 58 FTC Circuit Board Current ref dwg 703 1271 136 Model FGA 300V X Vertical Gas Analyzer User s Manua
37. at a minimum rate of 150 cc min 0 3 SCFH Model FGA 300V X Vertical Gas Analyzer User s Manual 21 Chapter 2 Installation 2 6 1 Mounting the Analyzer cont 4 Anexplosion 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 16 Reference Purge Air Inlet Pre Sealed Cable Gland Main Analyzer Unit Calibration Gas Inlet Pre Wired Accessory Box Top View Figure 16 Explosion Proof Flameproof Enclosure 2 6 2 Mounting the Remote FTC Box In addition to the Main Analyzer Unit and the attached Accessory Box the FGA 300V X system includes a separate Remote FTC Box Mount the FTC Box as close to the analyzer as possible and connect it to the Accessory Box with 0 75 mm or18 awg cable for distances up to 25 m 80 ft Note The remote FTC Box may be located up to 40 m 110 ft 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 F 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
38. corresponds to the value on the front panel display UV pu Oy Ne m Remove the resistors from TB1 and the jumper from W103 116 Model FGA 300V x Vertical Gas Analyzer User s Manual Appendix A Rotary Switch Settings li S4 S8 S2 Sl ALARM ANALOG DISPLAY FUEL oooo00n0 eo o oe c o ceo e s r o temi TB3 e HB
39. dimensions IMPORTANT This symbol indicates Caution risk of electric shock AN 22 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 6 3 Mounting the Display Electronics Console Ideally the 300D Display Electronics Console should be located within 5 m 15 ft of the FTC Box However the use of shielded cable permits distances up to 150 m 500 ft 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 Mounting Dimensions and Drawings for the Display Console mounting dimensions Note For units without the optional combustibles detector the Display Console may be located up to 600 m 2 000 ft from the FTC Box without significant signal degradation if shielded cable is used The Display Console has four rotary switches located on its printed circuit board which are used to set fuel type Switch 1 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 insulati
40. part to be replaced IMPORTANT Jf the power must be disconnected to replace a part perform the replacement as quickly as possible The FGA 300V 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 300V 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 AN AN 6 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 300V X operation Compliance with the following instructions will help to eliminate such problems 1 Do not use any thread sealant on the threads of probe components or on any Joints in the sample flow path Teflon tape will melt at the normal probe operating temperature and other thread sealants give off combustible vapors that can cause reading errors 2 Do not handle the oxygen sensor or combustibles detector with bare h
41. 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 raising the temperature of the active element above that of the reference element See Figure 7 Flue Gas Flow Reference Element Inert Coating Active Element Platinum Catalyst gt 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 300V x Vertical 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 300V and explosion proof flameproof FGA 300VX 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
42. point 4 Move the jumper at location W101 from the 2 3 position back to its original 1 2 position Model FGA 300V X Vertical Gas Analyzer User s Manual 33 Chapter 2 Installation 2 8 Installing Additional Components The typical FGA 300V X Vertical Flue Gas Analyzer supplied by GE consists of three major components Main Analyzer Unit Accessory Box Remote FTC Box 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 Flowmeters Pressure Gauges e 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 22 on page 35 should serve as a good general guideline for most situations The all inclusive diagram in Figure 22 on page 35 is not intended to imply that all of the components shown are required in every situation Only those items deemed appropriate for the intended application need be considered Note Figure 22 shows a system with a 300VX explosion proof flameproof unit and remote FTC Box and a standard Display Console Although other combinations of stand
43. savings for the overall operation To meet these specific needs GE the FGA 300V X 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 measure these two parameters the FGA 300V X uses azirconium oxide zirconia oxygen sensor 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 i e there must be enough oxygen present to burn the fuel Each FGA 300V X analyzer may be equipped with one or both of these devices The FGA 300V X Vertical Flue Gas Analyzer is available in both the standard weatherproof FGA 300V and the optional explosion proof flameproof FGA 300VX Physically the FGA 300V 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 300V X consist of at least two enclosures the larger of the two is the Main Analyzer Unit and the smaller enclosure is the remote Furnace Temperature Control FTC Box In addition a Display Electronics Console may be included in the system Model FGA 300V X Vertical Gas
44. the cartridge heaters in the heater block on the bottom of the Main Analyzer Unit The thermostat wires come out the side of the heater block near terminal block TB1 the side opposite the combustibles detector Trace the thermostat wires from the end of the thermostat to pins 12 and 14 on terminal block TB1 in the Main Analyzer Unit Disconnect ONLY the thermostat wires at pins 12 and 14 on terminal block TBI IMPORTANT Do not disconnect any other leads at these terminals 6 Remove the old thermostat by pulling it out of the heater block 6 5 8b Installing the New Thermostat 1 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 Strip the ends of the two new thermostat wires Insert the new thermostat leads into pins 12 and 14 on terminal block TB1 and tighten the screws securely Polarity is not important Install the Main Analyzer Unit cover by completing the steps in the Removing the Cover section on page 76 in reverse order and reconnect the main power to the unit This completes the replacement of the thermostat 94 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 4 FTC Board The major component associated with the operation of the sensor furnace is the Furnace Temperature FTC control board which is located in the Remote FTC Box Note Some older un
45. 00V X Vertical Gas Analyzer User s Manual 119 Appendix B Outline and Mounting Dimensions sayau sJejeuurpuu u BJD suorsueuuiq qI 87 64 22 1uBI A MIA WOLLOS S21 801 MIA LNOYS MalA 3015 S3DDld Z S20 98 S 2D d Z 80 226 Ut T JO WOT Uu9 0 1 201192 _ Pog Joule L A by 92DuJn4J Josueg MalA dOL SelloG Jez jeuy seg anja SPOT S92 S 01 90 Standard Weatherproof Figure 46 Main Analyzer Unit Model FGA 300V X Vertical Gas Analyzer User s Manual 120 Appendix B Outline and Mounting Dimensions sayau1 sje1euuipiiu ur BD suorsueuuig 16 s OST S91 z E I 6 001 TSS OnT ie dae papas A10 904 pup o9 e qp5 xog JOSS3IIY ZL 19JqDD 1dN v 4 Mass Bulyoo7 AA 15S Bunoo7 yun JazAjouy UID N M S Hulyd07 j xog oss 29y aBind AV eA DA Jayjoarg SOLJUJ B GDD IdN v jun Ja
46. 114 SA3 IW ADIHL NSOTONS LWX WV OSIQNOJ 0419313 L ONILVW 13 T11V8Vd LIGGV ON AVI83 L VIA X226 LOT 916 8 NBLOT LOT 226 X3INI NOILVOIJILHS3O d3 WYW Q3l3IGOW 39NSOTINI SALON Proof Flameproof Ion Explos it 2 of 2 in Analyzer Un igure 48 Ma F Model FGA 300V X Vertical Gas Analyzer User s Manual 122 Appendix B Outline and Mounting Dimensions 811 0 4 180 22D 0 2 f x E x 25 T O7 ql S 9T 63 S 1uBI A SOUDU sJe1euut iuu u BJD suorsueuuiq S 8 2T2 i 988 S22 T fe ld 7 150 8 f o3 Pm i 1 al 00 S9l19S BOWNUNd H31V3H JezKjeuy seg anja dps y TO J 2 P cc OTT was 86 S 2ST xl Standard Weatherproof Figure 49 Remote FTC Box 123 Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions sayoul se3euuijiiu ur BD SUDISUBWUIG Td 9 1dN p 9 8172 9 02 22 S91 zt 872 9 a Y A m 20 TT 082 m S76 O72 ld tr 1170 21D el Ove PN E811 oog 20 082
47. 300V 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 2006 95 EC the analyzer 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 FGA 300V 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 2006 95 EC Model FGA 300V X Vertical Gas Analyzer User s Manual 141 no content intended for this page 142 Model FGA 300V X Vertical 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 300V X analyzer Specifically the following components within the remote FTC Box have evolved e FTC printed circuit board sensor furnace power transformer Because of the reliability of the FGA 300V X many units with the previous FTC ci
48. 49 02 Cal Port Flowmeter 1781 505 Plug 8mm Serto 1420 619 Flow Shield 1781 527 Internal Calibration Tubing 1781 511 Calibration Stub 6mm 100 1781 504 Pile ele el ele ele e aie Pe ete rn DN rn A ea na nea Bulkhead Fitting Cal Port Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 7 Ordering Information The information below shows how the 300D Digital Display Linear Board Part Number is configured from the options specified 1703 011 Table 20 300D Linear Board Ordering Information CATEGORY OPTIONS 1 Rack Bench or Panel 2 Weatherproof or Explosion Proof 2 Oxygen only 115 VAC 3 Oxygen only 220 VAC 4 Combustibles only 115 VAC 5 Combustibles only 220 VAC 6 Oxygen and Combustibles 115 VAC 7 Oxygen and Combustibles 220 VAC Package Configuration 0 Single Oxygen and Single Combustibles Alarm Alarms 1 Dual Oxygen Alarms 2 Dual Combustibles Alarms The information below shows how the FGA 300V X Temperature Control Board Part Number is configured from the options specified 1703 1271 Table 21 FGA Temperature Control Board Ordering Information CATEGORY OPTIONS 2 Thermocouple 110 VAC Thermocouple 3 Thermocouple 220 VAC RTD 4 RTD 110 VAC 5 RTD 220 VAC 1 Remote 2 Local Please specify the Seria
49. Analyzer User s Manual 1 Chapter 1 General Information Overview cont Flue Gas Analyzer Series 500 WARNING SURFACES ARE VERY HOT y KEEP ANALYZER ENERGIZED LJ LJ Standard Weatherproof Model 300V Front View n Explosion Proof Flameproof Model 300VX Side View Figure 1 Main Analyzer Unit 2 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 1 General Information 1 2 Description of System The Main Analyzer Unit houses the sample system which consists of the components shown in Figure 2 The functions of the sample system components are as follows e 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 aplatinum catalyst combustibles detector to monitor imperfect combustion of the fuel by burning it in the presence of excess oxygen atemperature controlled sensor furnace to maintain the oxygen sensor at a stable operating temperature and to act as the engine for convective sampling a convection loop to circulate the sample gases through the sample system Oxygen Sensor Convection Loop Sensor Furnace Combustibles Detect
50. C board fuse is located on the FTC board in the remote FTC Box CAUTION To replace the FTC board fuse the power to the FGA 300V 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 62 on page 144 and complete the following steps to replace the FTC board fuse 1 Disconnect the main power to the FGA 300V 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 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 Model FGA 300V X Vertical Gas Analyzer User s Manual 145 Appendix F Previous Configurations F 4 Replacing the FTC Board The Furnace Temperature Control FTC board is located in the Remote
51. F include a 1 1 4 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 Hardware Manifold shown with o other components Hagtar Block removed for clarity Hardware Mounting Flange Gasket Mounting Surface Mating Flange 1 3 of diameter or 30 60 cm 1 2 ft whichever is less Probe Sleeve Probe Shroud Approx 3 mm F pp GAS FLOW Figure 15 Sample Probe Assembly 20 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 6 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 300V requires an external power disconnect device such as a switch or circuit bre
52. 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 300V 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 AN The only tool needed to replace the FTC board is a nutdriver or similar tool Refer to Figure 62 on page 144 and complete the following steps to replace the FTC board 1 Disconnect the main power to the FGA 300V 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 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
53. GE Measurement amp Control Solutions Gas Analysis FGA 300V X Vertical Flue Gas Analyzer User s Manual a k 910 105 Rev F Imagination at wor August 2011 FGA 300VIX Vertical Flue Gas Analyzer User s Manual 910 105 Rev F August 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 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 sur
54. OTS sve ce s oot t toy ma ara V nisa a AE qaqapa ak l aa ARIS 69 5 511 O outeofsRarige Indie GEOES c uvis vate eA RN EROR VON RC AS P RUF FRUI AR leper ER en 69 5 5 2 0123580 Negative REIGN PEA en Cees esu uc une cR LM NE a EE LED MS 70 5 3 3 L 0 Negative Out Of Ronge Indicator coorta a is RR E een en e i ER da 71 5 3 4 Low Combustibles Reading but Correct Oxygen Reading 72 Calibration A A tue Aaa alui Masta eters aig d it edie ca eset ONU AEE 73 5211 EVerythingIeFipes m AM Sa SSE N ie Mola bot se Mit ME asa s 73 LEO FloW ES AE uz ext o yum a uuu a cc sont tad ease cents suatu AR Lor baa 73 54 Seda Space Prol umanku m ee Lied cre uya Sus oe Ltt leche a Susa al doc ene 73 vi Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 1 OVER di EN ES 6 2 Preventing Common Problerns 6 3 The Main Analyzer DOE s u jews da a od ES REMOVING the UBI s u tat Acdece tiled idees tont aet fun cea 6 3 2 Replacing the Oxygen Sensor ClipS 6 3 3 Replacing the Oxygen Sensor 6 3 4 Replacing the Combustibles Detector 6 3 5 Replacing the Temperature Sensor 6 3 6 Replacing the Sensor Furnace 6 3 7 Replacing the Cartridge Heaters 6 3 8 Replacing the
55. 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 53 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 Refer to Figure 59 on page 137 Wiring Diagrams and Circuit Boards and verify that the combustibles detector is correctly wired at terminal blocks TB1 in the Main Analyzer Unit the remote FTC Box and the Display Electronics Console Make sure that none of the wires interconnecting the three terminal blocks are loose or broken 2 Inthe Main Analyzer Unit disconnect the common wire from pin 9 of terminal block TBI and attach one lead of a multimeter to the disconnected wire Model FGA 300V X Vertical Gas Analyzer User s Manual 69 Chapter 5 Troubleshooting 5 3 16 Check the Combustibles Detector cont 3 Attach the other lead of the multimeter to pin 10 of terminal block TB1 record the resistance of the reference element and do one of the following Ifthe resistance
56. URFACES ARE VERY HOT KEEP ANALYZER ENERGIZED amp LI Calibration Port Standard Weatherproof Enclosure Front View Im Calibration Port Explosion Proof Flameproof Enclosure Side View Figure 23 Calibration Port Location 44 Model FGA 300V X Vertical 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 41 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 I 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 23 on page 44 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 measure across pins 1 and 2 on terminal block TB1 in th
57. afety codes and regulations for installing electrical equipment which apply All procedures should be performed by trained service personnel 2 6 4a Connecting the Analyzer to the Remote FTC Box Make wiring connections from terminal block TB1 in the remote FTC box to terminal block TB1 in the main analyzer unit For an explosion proof flameproof main analyzer unit connect the remote FTC box to terminal block TB1 in the accessory box the smaller box attached to the main analyzer unit Refer to Table 1 and Figure 17 on page 25 and Figure 18 on page 26 for the terminal block locations and the proper pin connections An Interconnection Diagram Figure 20 on page 29 has been included for help in making the proper connections Wiring diagrams can be found in Figure 59 on page 137 and Figure 64 on page 150 24 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 6 4a Connecting the Analyzer to the Remote FTC Box cont Table 1 Main Analyzer Unit to FTC Box Connections From Main Connect Analyzer TB1 To FTC Box TB1 Oxygen Sensor Temperature Sensor Combustibles Active Combustibles Common Combustibles Reference Heater Live Neutral Furnace Live Ground
58. aker 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 300VX IMPORTANT This symbol indicates Caution risk of electric shock AN After installing the probe and probe sleeve into the analyzer as described in the previous section mount the analyzer as follows 2 6 1 Mounting the Analyzer 1 Slide a suitable high temperature gasket over the probe assembly so that it rests against the mounting flange on the bottom of the main analyzer assembly Note If the mating flange was purchased with the analyzer an appropriate gasket is included 2 Insert the probe and sleeve into the hole in the furnace boiler ceiling until the gasket is sandwiched between the two flanges 3 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 mounting and 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
59. and U isplay Enclosure inD ith FTC Board ion Diagram w Interconnect igure 61 F 139 Model FGA 300V X Vertical Gas Analyzer User s Manual no content intended for this page 140 Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix E Default Settings Appendix E Default Settings E 1 Overview For CE Mark compliance the FGA 300V 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 300V X meets Performance Criterion A except at a limited number of frequencies Criterion B per EN 61326 E2 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 Ifthe instructions in this appendix are followed the unit will comply with the EMC Directive 2004 108 EC Table 34 Wiring Modifications for EMC Compliance Connection Wiring Modification Use shielded cable to connect power to the FGA 300V 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
60. ands Although some scratches on the platinum coating can be tolerated rubbing the coating should be avoided Model FGA 300V X Vertical Gas Analyzer User s Manual 75 Chapter 6 Parts Replacement 6 2 Preventing Common Problems cont 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 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 6 3 The Main Analyzer Unit Those components associated with the basic sample system are located in the Main Analyzer Unit This section describes the proper procedures for replacing these parts 6 3 1 Removing the Cover In order to access the sample system components the cover must first be removed from the Main Analyzer Unit e Standard weatherproof FGA 300V a Remove the two 2 screws on each side of the cover near the base of the Main Analyzer Unit b Lift the cover straight up and off the base with the handle provided Explosion proof flameproof FGA 300V X a Loosen the locking set screw on top of the Main Analyzer Unit and using a long screwdriver across the slots provided unscrew the cover from the enclosure b Loosen the locking set screw on th
61. ard and flameproof enclosures for these components are possible the fundamental connections shown in Figure 22 remain unchanged 3 4 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 2 Installation _ Display Electronics Console o Flue Gas Analyzer Remote FTC Box Pressure Gauge Flowmeter 1 4 Compression Fitting 1 4 316 S S Tubing Flame Arrestor Accessory Box Main Analyzer Unit Cable Gland m me fo 10 50 cc min Flame Arrestor On IE 2 es Shut Off Ball Valve oun Pressure Gauge 40 240 cc min Flowmeter Needle Valve aja Needle Valve 5 Calibration Gas Supply Reference Air Supply Figure 22 A Complete FGA 300VX System Model FGA 300V X Vertical Gas Analyzer User s Manual 5 Chapter 2 Installation no content intended for this page 36 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 3 Operation Chapter 3 Operation 3 1 Overview The FGA 300V 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 additio
62. arked 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 300VX Model FGA 300V X Vertical Gas Analyzer User s Manual 37 Chapter 3 Operation 3 3 Taking Measurements Allow the FGA 300V X to warm up sufficiently before taking any measurements Readings are output 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 graphs in Appendix C The Nernst Equation to convert the analog output reading into percent oxygen For a more precise mV to oxygen conversion use one of the following formulas depending on which standard temperature has been selected for your particular system if 770 C 1 418 F use 20 9 E779 mV 51 745 x EE O2 in Sample a if 812 C 1 494 F use 20 9 Eg12 mV 53 829 x EE O2 in Sample 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 38 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 3 Opera
63. b Medica Vlad o RS A e d 37 Se SPOWSHPOUDENe Ss tuya p EL h yea EIL ad eae da ee o c voc A Led 37 337 aking Megsurelmmenten Sor da o Qu e ES AO 38 34 Sing the Display dnd Keypad AA qa macan Usa ghee 39 Model FGA 300V X Vertical 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 RI Pe UE 41 Recommended Ca lO ASES Pe ui or POCO AAA E edv ob arb eq 41 Solibratingd the Oxygen SEAS nes rac b ed La een ia ved eel dO UMP duties niti adc 43 4 3 1 Regulating the Calibration Gas Flow Rote ci Yee ane ee edere b eee 43 4 So CI IDEGU OB CHECK ssi testi e o e aac DS el e o M LE DEN niche 45 Calibrating the Combustibles Detector 48 4 4 1 Checking the Operating Temperqture 48 DAZ ZePO CHOC Re een C A E E T E TAT iE 50 APA ol 1 AAA tact eden a S Medan Peau a E OE a Sens A EA 50 Chapter 5 Troubleshooting IV bite EAS AAA TARA AR OR RCNA EH OT ATA ARS AAA OG El 51 OY O MES DE 53 A EET EE ES 53 52 2 PPRPP and Normal Reading RENIN dos si ai ota 62 A E O 63 5 2 4 Oxygen Concentration Reads Constant 20 996 ai A Ve ee e OR ci R8 65 5 2 5 0xyg n Readding Ab ve 20 9 cutie A ecw b ER CAPAS 67 5 25 DR gemRegding Too Dosis Credo NL PE CE REC CE CERE DOE Et bebe Die od edita 67 5 2 Oxygen Redding Too IQ os iso e ute queso dut prex Qon PER ONE deh eG odes eee ead 68 Combustibles E
64. bai te beas 76 WINNS sacs heh tbe aga dad 24 Measurements Displaying gt sucus uere SEX Petts BO 39 Takih gisa ta 38 N Nernst Equation Graphical Form 132 Numeric Form 38 131 O Operating Principles 6 A aq Cae a Sua a t a e ss a ay 105 Ordering Information 101 106 Oxygen Sensor Alternate Temperatures 132 Calibration Saves SOL x t CV 43 Clips RepHCIBE oiv oss Vu da ea aed 77 Desert td ode AO a ete 1 6 Replacing ud AR 79 TES a RA da De 59 Voltage Output 47 P Plumbing Leaks 65 Power Input A DU pce a Cae ORE 27 Probe Assembly D esceripti ne uy sa aD sad a ks eee 14 Installing u SAR 19 PURGE ATE e e Tm PO uA u pde saca ah 22 154 R Recorders Analog Output Choices 30 WIR UE apa Saya Ga UR Rub re e 30 Reference AI ois uy Ec S PUER EX MU DUE d es 22 Replacing See Part Name Return Policy amp a vr tU EDS S 157 RTD Replacing 2a asas E na ete aa ee 84 A i CR RUD AER 55 S Safety Auxiliary Equipment 111 General Issues 529 2 UE qud A S Re ta Oe 111 Personal Equipment 111 Sample Gas Contamination 67 Sample System a2 4e wa ue hee Rate 3 11 Sensor Furnace Adjusting Temperature 47 148 Checking Temperature 55 Replacing A RN puis eed 86 Wilh ay
65. 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 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 FTC board 146 Model FGA 300V x Vertical Gas Analyzer User s Manual Appendix F Previous Configurations F 5 Replacing the Transformer The sensor furnace power transformer is located near 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 300V 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 adigital multimeter IMPORTANT This symbol indicates Caution risk of electric shock GS Refer to Figure 62 on page 144 and complete the following steps to replace the transformer 1 Disconnect the main power to the FGA 300V X 2 Open the hinged cover on the standa
66. cal Gas Analyzer User s Manual Current Draw it Board Ircu isplay Ci D 60 igure F 138 Appendix D Wiring Diagrams and Circuit Boards AV 1dSIG indino T Zal N39AXO C cal ON T g 2 e 8l ON 28l NIVIV N3SAXO AlddNS SNIVIA ONISN3S SUNLONYLSVYSNI 39 A8 O3NAANS LON LNSWSYINOSY AYVW 39 OM T OTOT 931 T OTOT9 N3 HLIM SONVIMdWOD YOW G3YINOIY HOLIMS 123NNOOSIG SNIVW d3ZA IVNV XNO0 LON AINO A00 ALON 3Sf1d ON 3AU 1331V3H TV8 103N Q3Sn3 SAN 32VNSnd e T8L 181 YATIONLNOD JDVNYNS YOSNAS NIDAXO T 2al 23 e c81 23 1AdINO c8l ano 1 29 NyVIY ON t 28l gWiod DAA G L ON 9 al SLAGLNO 4V38 LV SIVNIWYSL Goose day SAYLNID WWO9X09 S3ISIN3 LdN 7 XZ S9dl 9 91 911 p X33 NMOHS LON 000 dx3 YOSNAS IYNLVIIANIL S T8l 9 18 NOWWOD 181 8 Tal SLAdNI S38 1N32 WWeg S3l81N3 WWO D xt 99dl Goose diM 00 Salas s JAV S3lg1N3 WWUZZ xe Sdl AO0 V93 cut rut Ki aue uA cU cA damus dcc Fe Mec A II oe ate NN 30123130 S318l1Sn8I402 S3IHLN3 LdN 7 XE S9d1 8 S12II P x33 XAO0 V94 n SaaS sezkeuy seo
67. ch is approximately the same length as the heater block is located in the heater block on the bottom 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 e wire cutters wire strippers Watlube Heat Transfer and Release Agent CAUTION Toreplace the thermostat the power to the FGA 300V 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 AN Model FGA 300V X Vertical Gas Analyzer User s Manual 93 Chapter 6 Parts Replacement 6 3 8 Replacing the Thermostat cont Use the procedures below and refer to Figure 41 on page 91 to complete the thermostat replacement 6 3 8a Removing the Old Thermostat 1 2 3 5 Disconnect the main power to the FGA 300V X Remove the Main Analyzer Unit cover as described in the Removing the Cover section on page 76 The thermostat is located next to one of
68. ck TB1 in the Remote FTC Box and across pins 3 and 4 of terminal block TB1 on the FTC board See Figure 30 for the terminal block locations and record the two voltage readings seacososs S8 FTC Board Standard Weatherproof Remote FTC Box Explosion Proof SS Flameproof Remote FTC Box 1 FTC Board T 5 Fuse O ac z OBBBEDDBDSE Figure 30 FTC Board Fuse and TB1 Locations Model FGA 300V X Vertical Gas Analyzer User s Manual 61 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 see Figure 59 on page 137 Wiring Diagrams and Circuit Boards Then one of the conditions listed in Table 16 should occur Table 16 FTC Output Voltage Readings Voltage Reading Recommended Action The FTC board is good The Display Electronics Console may be defective contact the factory for assis
69. ct 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 and the corresponding potential calibration errors shown in Table 8 are introduced Table 8 Calibration Uncertainty Error As shown in Table 8 a calibration uncertainty of about 3 5 is introduced by the calibration gas uncertainty alone 42 Model FGA 300V X Vertical 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 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 Rate A temporary connection is usually made for calibration A blank plug is supplied with the FGA 300V 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 a
70. d displaying the 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
71. d open end wrench on the nut directly below the first wrench Note The wrenches should be parallel to each other but the bottom wrench should be positioned with its end rotated about 2 in in a counterclockwise direction from the upper wrench Refer to Figure 38 for a view of the wrenches from both the side and the bottom of the manifold assembly 6 While holding the top wrench steady turn the bottom wrench two inches toward the top wrench so that the two wrenches are aligned with each other Note Do not attempt to move the top wrench during the above step Be sure to hold it in its original position 7 Repeat steps 5 and 6 to loosen the upper nut in the center of the convection loop see Figure 38 Model FGA 300V X Vertical Gas Analyzer User s Manual 87 Chapter 6 Parts Replacement o uu uuuau aaucsr s MS 6 3 6a Removing the Old Sensor Furnace cont Figure 39 Removal of Sensor Furnace 8 Unscrew both loosened nuts completely and lift the sensor furnace off the manifold with the upper portion of the convection loop still attached see Figure 39 88 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 6a Removing the Old Sensor Furnace cont
72. ded calibration gas 5 O 95 No the oxygen sensor output voltage should be 32 14 0 2 mV at 770 C or 33 44 0 2 mV at 812 C Note For an FGA 300V X analyzer 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 4 If necessary adjust the sensor furnace operating temperature using potentiometer R4 on the FTC board in the following manner see Figure 24 on page 46 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 change 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 outp
73. der 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 4 to make the proper connections and refer to Figure 19 on page 28 for the terminal block location on the 300D Display circuit board Table 4 Recorder Connections Output Variable 300D Display TB2 Oxygen Oxygen Combustibles Combustibles The scale for 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 6 6 Connecting Alarms There is one alarm for the oxygen channel and one for the combustibles channel Once the alarms are connected the alarm trip points must be set Refer to Table 5 and Figure 19 on page 28 to make the proper connections Table 5 Alarm Connections Alarm Output 300D Display 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 30 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 7 Setting Alarms The instructions in this section desc
74. detector 4 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 2 5 Installing the Probe and Probe Sleeve 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 ft Confirm that the probe and sleeve are the correct lengths Then refer to Figure 15 on page 20 and complete the following steps 1 Asshown in Figure 15 on page 20 attach a flange or fixing plate to the bottom of the Main Analyzer Unit Orient the flange 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 bottom of the analyzer When properly installed the probe sleeve should extend approximately 3 mm beyond the end of the probe 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 Model FGA 300V X Vertical Gas Analyzer User s Manual 19 Chapter 2 Installation 2 5 Installing the Probe and Probe Sleeve cont 3 Units intended for operation at temperatures below 950 C 1 750
75. dition of the oxygen sensor This parameter indicates the combustion air requirement index Combustibility Index CI 14 02 0 67 x 9605 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 Oxygen Sensor Test advance that sensor replacement is necessary Model FGA 300V X Vertical Gas Analyzer User s Manual 39 Chapter 3 Operation no content intended for this page 40 Model FGA 300V X Vertical 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 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 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
76. dy 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 27 on page 55 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 24b 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 Main Analyzer Unit 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 3 If the oxygen reading drops ensure that all fittings are tight and replace the Main Analyzer Unit cover If the oxygen reading gradually returns to 20 9 try tightening the fittings an additional 1 8 turn If the prob
77. e 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 25 on page 49 for the location of R111 and adjust it in the appropriate direction Turn R111 clockwise to increase the ppmy reading or 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 A span calibration gas consisting of 1000 ppmy CO 500 ppmy H 1 O balance N is recommended To perform a span check complete the following steps 1 Introduce the span calibration gas 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 adjust 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 25 on page 49 for the location of R105 and adjust it in the appropriate direction Turn R105 clockwise to increase the ppm
78. e Remote FTC Box or using a voltmeter measure across pins 1 and 2 on terminal block TB1 in the Main Analyzer Unit See Figure 24 on page 46 for the location of the terminal blocks Model FGA 300V X Vertical Gas Analyzer User s Manual 45 Chapter 4 Calibration 4 3 2 Calibration Check cont oeos _elo_ oes y amta Saje 2 ees Soo alls seo FTC Board 9 E c Standard Weatherproof Remote FTC Box Explosion Proof S Flameproof Remote FTC Box Z FTC Board Sead 209599569656 99500008800 ya lao 96068 Figure 24 FTC Board R4 and TB1 Locations 46 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 4 Calibration 4 3 2 Calibration Check cont 3 Calculate the expected oxygen sensor voltage output with one of the following equations Note Be sure to use the first equation for units operating at 770 C and the second equation for units operating at 812 C 20 9 RAS EE O2 in Cal _ 29 _ Pees S O2 in Col z When using the recommen
79. e and probe sleeve carry the sample gas into and out of the analyzer see Figure 12 300V X units intended for operation at temperatures below 950 C 1 742 F include a 1 1 4 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 Probe Sleeve Figure 12 Permitted Gas Flow Angles 14 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 2 Physical Description cont The standard weatherproof FGA 300V is equipped with a short section of 1 1 2 NPTM threaded pipe projecting from the manifold assembly at the bottom of the analyzer see Figure 13 On the explosion proof flameproof FGA 300VX 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 availabl
80. e furnace and cools 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 A dE T 98 E ee NA OR e ISA CR CN E lt a ADS Figure 5 Zirconia Oxygen Sensor 6 Model FGA 300V x Vertical 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 02 suum Sample O gt oosoooso Jeocososcoso Outside Cell Amcooosoommsooon soOo00ooOsooOmooomsoL oopsmoo 4 Jm Jecmmrt O2 umumi BOOOG Bepooo umur O2 0275000 ooo omoo opoo mE gafn omoo Atmospheric O soos BOBO x oo00 ooo Inside Cell aa DONO 20 996 DENDO wooo DONO noma mouudg oo00 UD osoo BOOD Urs oomoo DOOB oomoo BODO nomo COBO Ogoo 27 N Zirconium Oxide Ceramic with Ee ZII Lattice Imperfections From Outside Electrode X F
81. e options are 3 300 Ib ANSI 4 150 lb ANSI and DN80 PNI6 flanges Main Analyzer Unit Flue Gas Analyzer Series WARNING SURFACES ARE VERY HOT KEEP ANALYZER ENERGIZED Threaded Pipe Mounting Flanges e Short Pipe Metal Wall Probe Sleeve Figure 13 A Typical Flange Mounted Unit Model FGA 300V X Vertical Gas Analyzer User s Manual 15 Chapter 2 Installation 2 2 Physical Description cont The FGA 300V X is wired at the factory for one of four possible operation voltages e 100 VAC 110 120 VAC e 220 VAC 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 FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 3 Installation Site Install the Main Analyzer Unit in the furnace or boiler ceiling or in the top of a horizontal 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 downward and a
82. e side of the Main Analyzer Unit near the bottom and unscrew the enclosure from the base of the unit c 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 AN AN 76 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 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 pliers wire cutters wire strippers crimping tool Power should remain on while replacing the oxygen sensor clips Refer to Figure 33 while completing the following steps Inner Clip e Outer Clip Figure 33 Oxygen Sensor Clips
83. e 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 300V X Vertical 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 ext
84. econnect the main power to the system The system may now be placed back into service Model FGA 300V X Vertical Gas Analyzer User s Manual 95 Chapter 6 Parts Replacement 6 4 2 Replacing the FTC Board The Furnace Temperature Control FTC board is located in the 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 300V 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 AN The only tool needed to replace the FTC board is a nutdriver or similar tool Refer to Figure 42 on page 97 and complete the following steps to replace the FTC board 6 4 2a Removing the Old FTC Board 1 Disconnect the main power to the FGA 300V 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 hex nuts and washers located i
85. ective and must be replaced either 770 C or 812 C see Replacing the Temperature Sensor on page 84 Note Ifa voltage reading other than those listed above is obtained refer to Figure 28 or Table 13 on page 58 to determine the operating temperature of the sensor furnace A standard FGA 300V X operates at a temperature of either 770 C or 812 C VOLTAGE mV 800 900 TEMPERATURE C Figure 28 Thermocouple Voltage vs Temperature Model FGA 300V X Vertical Gas Analyzer User s Manual 57 Chapter 5 Troubleshooting 5 2 16 Check the Temperature Sensor cont Table 13 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 58 Model FGA 300V X Vertical 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 connecti
86. element is shorted 0 ohms or open OL the combustibles detector is defective and must be replaced refer to Replacing the Combustibles Detector on page 81 4 Move the multimeter lead from pin 10 to pin 7 of terminal block TBI record the resistance of the active element and do the following If both readings are 1800 1900 ohms and the difference between them does not exceed 50 ohms disconnect the multimeter and reconnect the common wire to pin 9 of terminal block TB1 The combustibles channel may be out of calibration refer to Replacing the Combustibles Detector on page 81 If the element is shorted 0 ohms or open OL the combustibles detector is defective and must be replaced refer to Replacing the Combustibles Detector on page 81 If the steps in this section do not correct the 1 0 combustibles error consult the factory for assistance Model FGA 300V X Vertical Gas Analyzer User s Manual 71 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 the combustibles detector was calibrated at too low a flow rate To correct this error condition complete the following steps IMPORTANT This symbol indicates Caution risk of electric shoc
87. ence element open or active element shorted combustibles channel severely out of calibration detector incorrectly wired detector physically damaged or improperly installed detector aging calibration flow too low no response Low Combustibles Reading but Correct Oxygen Reading no response a 0 error indicator also appears on the combustibles display see first O error Note Although the E2 sensor aging and E3 probe plugging error codes have been defined they have not yet been implemented 52 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 Oxygen Errors This section discusses each of the possible oxygen errors listed in Table 9 on page 52 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 faulty RTD TC temperature sensor faulty sensor furnace faulty furnace temperature control FTC board When the FGA 300V X detects this error alarms are activated analog outputs indicate a lack of oxygen on all ranges the stoichiometric interlock is
88. ent 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 Model FGA 300V X Vertical Gas Analyzer User s Manual 83 Chapter 6 Parts Replacement 6 3 46 Installing the New Combustibles Detector cont 7 Install the Main Analyzer Unit cover by completing the steps in the Removing the Cover section on page 76 in reverse order 8 Calibrate the new combustibles detector as described in Chapter 4 Calibration This completes the replacement of the combustibles detector 6 3 5 Replacing the Temperature Sensor The temperature sensor maintains the sensor furnace at a constant temperature Either a resistance temperature detector RTD 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 bottom 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 To replace the temperature sensor the power to the FGA 300V 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 dangerously hot surfaces and risk of electric shock respectively AN
89. er 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 300V X Vertical Gas Analyzer User s Manual 143 Appendix F Previous Configurations A 626 0 T V evoa FTC Board FTC TB1 Transformer Transformer TB1 FTC FTC Board oct Explosion Proof Flameproof FTC Box Figure 62 FTC Board amp Transformer Locations 144 Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix F Previous Configurations F3 Replacing the FTC Board Fuse The Furnace Temperature Control FT
90. f 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 balances 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 P4 E12 AE ne 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 gt partial pressure on flue gas side E voltage on reference face with respect to the flue gas face Model FGA 300V X Vertical Gas Analyzer User s Manual 131 Appendix C The Nernst Equation C 3 The FGA 300V X Equations The Nernst Equation specifically applicable to the FGA 300V X analyzer 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 E to millivolts This results in the
91. f the active element 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 wires to pin 9 of terminal block TBI 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 consult the factory for assistance 72 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 4 Calibration Responses Chapter 4 Calibration describes the procedures for calibrating the FGA 300V 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 an
92. following equation E MV 0 049605 e T e log Fa P2 The FGA 300V X uses one of two standard oxygen sensor operating temperatures Consult with a GE Panametrics engineer to determine which temperature is best suited to your situation if 770 C the equation above becomes E mV 51745 e log Ed Pa if 812 C the equation becomes E mV 53 829 e log al 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 equations for the FGA 300V X Flue Gas Analyzer above have been converted into a graphical format Use these graphs see Figure 56 on page 133 and Figure 57 on page 134 to quickly correlate the analog output voltage reading with the corresponding oxygen percentage at the operating temperature of the unit 132 Model FGA 300V x Vertical Gas Analyzer User s Manual Appendix C The Nernst Equation 0 0001 Oxygen Concentration Figure 56 Oxygen Sensor Output
93. g Dimensions Td Z 520 ST X O2W l 9 2 me YD puJa 562 SZ _ S62 o 9 2 09 E 9 2 09 i o Lm jaqo7 uono snyosoddy END A S071 cm v 8170 52210 MOPUIM r OTTO 2q51 uoo SINSOJDU3 1 81 599 523 S UDUI sJe3euuipjiuu ur 340 suoisuauuiq Buoy S9dl 104 Durg O 13 qI 9 0T 5 27 14blam 10 0T SS Bench Mount Figure 55 300D Display 129 Model FGA 300V X Vertical Gas Analyzer User s Manual no content intended for this page 130 Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix C The Nernst Equation Appendix C The Nernst Equation C 1 Overview The FGA 300V X Flue Gas Analyzer 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 I
94. g tools are needed for this procedure open end wrench torque wrench 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 AN s Model FGA 300V X Vertical Gas Analyzer User s Manual 81 Chapter 6 Parts Replacement 6 3 4a Removing the Old Combustibles Detector 1 Remove the Main Analyzer Unit cover as described in the Removing the Cover section on page 76 and locate the combustibles detector on the side of the manifold 2 Disconnect the four combustibles detector leads from pins 7 9 and 10 of terminal block TB1 in the Main Analyzer Unit 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 35 4 Slide the combustibles detector out of its housing Combustibles Detector Retaining Nut Manifold Figure 35 Combustible
95. ge is mounted so that the analyzer is vertical and not tilted when it is bolted in place CAUTION The mounting flange on a standard FGA 300V may be rotated readily but rotating the flange on an explosion proof flameproof FGA 300VX 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 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 4 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 300V X operation Compliance with the following instructions will help to eliminate such problems 1 Do not use any thread sealant on the threads of the probe components or on any joints in the sample flow path Teflon tape will melt at the normal probe operating temperature and other thread sealants give 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 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
96. gnal 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 62 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 5 Troubleshooting 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 31 on page 64 and perform the following tests 5 2 3a Check the Oxygen Sensor Every two hours the FGA 300V 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 sensor 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 2 and mV keys located on the
97. gure 44 Rotary Switch Locations 112 Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix A Rotary Switch Settings A 2 Selecting the Display Parameter Switch S2 allows the selection of the combustion process parameter to be automatically displayed Note The 300D Display 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 the installation However switch S1 is used in conjunction with switch S2 and applies only to the following three display parameters as chosen with switch S2 e Excess Fuel 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 Coal 1 Oil 2 3 4 Propane Butane Natural Gas Coke Oven Gas Model FGA 300V X Vertical Gas Analyzer User s Manual 113 Appendix A Rotary Switch Settings A 4 Adjusting the Oxygen Channel While switch
98. he Remote FTC Box Refer to Figure 18 on page 26 Figure 19 on page 28 and Table 2 for the terminal block locations and the proper pin connections Table 2 Display to FTC Box Connections From 300D Connect Display TB1 To FTC Box TB1 Oxygen Sensor Oxygen Sensor Combustibles Detector Reference Combustibles Detector Common Combustibles Detector Active Display Screen 4 Ground 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 6 4c Connecting the Power Power must be connected to both the Display Console TB4 and the Remote FTC Box TB1 Refer to Figure 18 on page 26 Figure 19 on page 28 and Table 3 for the terminal block locations and the proper pin connections Note Be sure that the line voltage at the intended installation site corresponds to the factory preset voltage setting Table 3 Power Connections From To 300D Display Voltage Supply TBA To FTC Box TB1 Live L L Neutral N N Ground chassis G e Protective Conductor Terminal Model FGA 300V X Vertical Gas Analyzer User s Manual 27 Chapter 2 Installation 2 6 4 Making Wiring Connections cont Display Electronics Console
99. he alarm trip point the alarm trigger mode must be set The oxygen alarm can be set for either high or low operation To set the alarm trigger mode 1 Locate jumper W1 on the 300D Display printed circuit board See Figure 21 on page 32 2 Setjumper 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 7 3 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 21 on page 32 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 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
100. he 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 300V X Vertical Gas Analyzer User s Manual 67 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 5 2 70 Check for Plumbing Leaks 1 Remove the Main Analyzer Unit cover in order to allow uncontaminated reference air to enter the unit 2 Ifthe oxygen reading drops tighten all fittings by 1 8 turn and rep
101. he sensor furnace being careful not to allow it to touch the sides of the furnace CAUTION Ifthe sensor furnace is hot insert the new oxygen sensor slowly Take 45 60 seconds to fully insert the sensor into the furnace If the sensor is inserted too quickly it will crack 3 After positioning the titanium washer against the sensor nut bottom nut finger tighten the oxygen sensor into its fitting on top of the sensor furnace IMPORTANT Jf the sensor furnace is hot allow the oxygen sensor to stand for at least two minutes before proceeding 4 Turn the fitting nut clockwise as viewed from above 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 Ib in 5 Reinstall the inner and outer clips onto the oxygen sensor body 6 Install the Main Analyzer Unit cover by completing the steps in the Removing the Cover section on page 76 in reverse order 7 Calibrate the new oxygen sensor as described in Chapter 4 Calibration This completes the replacement of the oxygen sensor 6 3 4 Replacing the Combustibles Detector The combustibles detector is located on the side of the manifold below the sensor furnace The combustibles detector unscrews easily from the manifold and slips out of its housing CAUTION The combustibles detector is very fragile Handle it with great care The followin
102. igure 38 on page 87 6 Place a wrench on the flat surface of the piping at the connection just below the sensor furnace see Figure 38 on page 87 7 Using a torque wrench set to 70 N m 600 in 1b tighten the nut while holding the first wrench steady 8 Repeat steps 6 and 7 to tighten the nut on the convection loop but set the torque wrench to 63 N m 540 in Ib 9 Reinstall the temperature sensor as described in the Replacing the Temperature Sensor section on page 84 10 Reconnect the two previously removed wires to pins 12 and 14 on TB1 in the Main Analyzer Unit 11 Using a digital multimeter check the resistance of the sensor furnace heating element Specific instructions may be found in Chapter 5 Troubleshooting Assuming that the correct resistance reading was obtained in Step 11 above replacement of the sensor furnace has been successfully completed Complete the procedure as follows 12 Install the Main Analyzer Unit cover by completing the steps in the Removing the Cover section on page 76 in reverse order 13 Reconnect the main power to the unit and recalibrate the oxygen sensor as described in Chapter 4 Calibration 90 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 7 Replacing the Cartridge Heaters A heater block is mounted on the bottom of the Main Analyzer Unit The cartridge heaters which are approximately 3 1 2 long cylinders and a thermostat are located
103. inside this heater block see Figure 41 Convection Loop Manifold Heater Block Heater Figure 41 Thermostat and Heater Locations The following items are required to replace the cartridge heaters e wire cutters is I wire strippers Watlube Heat Transfer and Release Agent CAUTION To replace the cartridge heaters the power to the FGA 300V 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 AN A Model FGA 300V X Vertical Gas Analyzer User s Manual 91 Chapter 6 Parts Replacement 6 3 7a Removing the Old Cartridge Heaters 1 2 3 5 Disconnect the main power to the FGA 300V X Remove the Main Analyzer Unit cover as described in the Removing the Cover section on page 76 Locate the cartridge heaters in the heater block on the bottom of the Main Analyzer Unit The cartridge heater wires come out the side of the heater block near terminal block TB1 the side oppo
104. is between 1800 and 1900 ohms proceed to step 4 Ifthe element is shorted 0 ohms or open OL the combustibles detector is defective and must be replaced refer to Replacing the Combustibles Detector on page 81 4 Move the multimeter lead from pin 10 to pin 7 of terminal block TBI record the resistance of the active element and do the following If both readings are between 1800 and 1900 ohms and the difference between them does not exceed 50 ohms disconnect the multimeter and reconnect the common wire to pin 9 of terminal block TB 1 The combustibles channel may be out of calibration refer to Calibrating the Combustibles Detector on page 48 If the element is shorted 0 ohms or open OL the combustibles detector is defective and must be replaced refer to Replacing the Combustibles Detector on page 81 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 1 Referto Figure 59 on page 137 and verify that the combustibles detector is correctly wired at terminal blocks TB1 in the Main Analyzer Unit the remote FTC Box and the Display Electronics
105. its also have a transformer in the FTC box to supply the 80 VAC required by previous FTC board designs See Appendix F Previous Configurations for additional information on these units 6 4 1 Replacing the FTC Board Fuse The Furnace Temperature Control FTC board fuse is located on the FTC board in the remote FTC Box CAUTION To replace the FTC board fuse the power to the FGA 300V 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 43 on page 98 and complete the following steps to replace the FTC board fuse 1 Disconnect the main power to the FGA 300V 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 r
106. k AN 1 Remove the cover from the Main Analyzer Unit 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 Replacing the Combustibles Detector on page 81 and to Figure 35 on page 82 and Figure 36 on page 83 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 Replacing the Combustibles Detector on page 81 Test the combustibles detector by completing the following steps a Inthe Main Analyzer Unit 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 o
107. keypad of the Display Console and record the voltage reading 3 If the voltage reading from Step 2 is more than 50 below the voltage reading from in Step 1 replace the oxygen sensor refer to Replacing the Oxygen Sensor on page 79 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 300V X Vertical Gas Analyzer User s Manual 63 Chapter 5 Troubleshooting 5 2 30 Check the Remaining Components 64 BLINKING READING Check O2 Sensor Temp Low No Reading Check Furnace Replace RTD TC 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 Check FTC Fuse Fix Main Power Fuse Good Replace FTC Board Figure 31 Blinking Reading Flow Diagram Model FGA 300V X Vertical 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 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 reme
108. l Appendix D Wiring Diagrams and Circuit Boards fal eal dW3L 3SVIYINI OL M 1SAFAY dWal TZ2T 20LT CO MNOIN ITIM WN H 9 13 Quv2 U3TIOSLNOO dW3L SOVNYNS S831V3H poui pea 1VISOWY3HL 39VN3NY Els Sy 21 Q18 3ALLOV MJIN XO tO SE rn CN e MAJON XO tO JIM eH 338 o a o a YOSNAS N39AXO YOSNAS 38N1VWIIAWIL 40193130 SAITIILSNEWOD LINN AWIASIO IWLISIG xog 913 310393 LINA S3ZATVNV v F 517 Re Current Drawing 1442 Figure 59 Wiring Diagram 137 Model FGA 300V X Vertical Gas Analyzer User s Manual uedo KjbuuoN uub y Sajqnsnquio uoululo uub y se qnsnquio Paso IDUWJON LUJD Y sejgnsnquio5 uedo AlpuujoN uuip v ueb xo uouduJo5 LID y usb xo Paso p AjjpuuoN woy usb xo uonduoseq
109. l number and Model number of the FGA 300V X when ordering FTC Location Model FGA 300V X Vertical Gas Analyzer User s Manual 101 Chapter 6 Parts Replacement no content intended for this page 102 Model FGA 300V X Vertical 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 420W 115 230 VAC 560W 120 240 VAC Fuses Anti Surge T Type 5x20 mm FTC Board 2 5 A 9115 VAC 1 25 A 9230 VAC Digital Display Board 200 mA 115 VAC 100 mA 230 VAC Warm Up Time Meets specified accuracy within one hour Area Classification for FGA 300VX II 2 G Ex d TIC T4 ISSepO4ATEX078X Note As a special consideration for certification the 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 Pollutio
110. lace the Main Analyzer Unit cover If the oxygen reading gradually increases repeat Step 1 and then replace the cover 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 its normal operating temperature the mV output will be too low and the percent oxygen reading will be higher than expected 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 performing the checks above contact the factory for assistance 68 Model FGA 300V x Vertical 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 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
111. lay 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 66 Model FGA 300V X Vertical 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 812 C would generate an oxygen sensor output of 33 47 mV However reversed oxygen sensor wiring would cause this reading to be 33 47 mV The Nernst equation calculation would then convert this voltage to an oxygen display of 87 61 To correct this problem check the oxygen sensor wiring at TB1 in the Main Analyzer Unit TB1 in the remote FTC Box and TBI in the Display Console for the correct polarity refer to Figure 59 on page 137 Wiring Diagrams and Circuit Boards 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 following steps 1 The sample gas may be contaminated with combustibles from the following common sources grease or oil in the sensor plumbing silicon based plumbing tape excess fuel in the burner T
112. lay Console is required for any FGA 300V X analyzer equipped with a combustibles detector The Display Console performs the following functions amplifies the oxygen sensor and combustibles detector outputs linearizes the oxygen signal shows percent oxygen on a four digit LED display shows ppmy combustibles on a 4 1 2 digit LED display provides a stoichiometric interlock at 100 ppm O 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 Flue Gas Analyzer 300 Figure 4 Display Console with O amp Combustibles Model FGA 300V X Vertical 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 imperfect 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 300V X A flue gas sample is drawn into the probe by gaseous diffusion
113. lem persists contact the factory for assistance CAUTION Do not tighten fittings more than 1 8 turn at a time Model FGA 300V X Vertical Gas Analyzer User s Manual 65 Chapter 5 Troubleshooting 5 24c 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 TBI in the Display Console See Figure 32 for the location of TB1 Figure 32 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 disconnected 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 Disp
114. low 650 C 2 650 to 950 C 3 950 to 1600 C 4 above 1600 C Sampling Method 1 Standard sampling method 3 Aspirated sampling method S Special sampling method Nominal Length 1 0 6m long 2 1 0m long 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 110 Model FGA 300V X Vertical 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 300V 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 Selecting the Fuel Type 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 adjusted 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 above adjustments 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 44 on page 112 to locate the switches
115. lyzer User s Manual no content intended for this page 152 Model FGA 300V X Vertical Gas Analyzer User s Manual A Accessory BOX es vowed loa isk Ga EV PAR q 13 Alarms Selecting Combustibles Trigger Mode 33 Selecting Oxygen Trigger Mode 33 Setting Combustibles Trip Point 33 Setting Oxygen Trip Point 31 NOTOS as cide ER RR EG NAP RU x 30 Analog Output Range Adjusting Combustibles Channel 116 Adjusting Oxygen Channel 114 R corders coa ag akka anu m ER 30 Ancillary Components 34 B Blowback System 62 C Calibration Combustibles Detector 48 Frequency aya ats ph deh uae hohe ag Satins 41 Gas Flow Rate gt vow aye wow dia 43 Oxygen Sensor 43 Plumbing Connections 43 Recommended Gases 41 Cartridge Heaters Replacing 91 CE Mark Compliance 141 Combustibles Detector Calibration s 4s abu a et a s 48 Descaplion 22 oS ous auia us ud Digo 1 8 Reference Element 69 ReplacihE ad pe Dau RE Se 8l Span Cheeks bray said wd wy bete ad adi 50 WINS s Gna can ep LAUR PES ERO ten Go b supay 83 Zero Cheek A pons ana ou teu es s 50 Common Problems 19 75 Connecting See Part Name ConvectionLoop 6 Model FGA 300V
116. mbustion 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 3 Remote Weatherproof FTC enclosure IP65 4 Remote Flameproof FTC enclosure Ex d IIC 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 Ib flange C S mounting 7 Two flanges with gasket ANSI 4 150 lb 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 Temperature 0 Standard temperature setting 812 C Control Setting S Special temperature setting 700 770 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 Furnace Controller
117. n make sure all electrical and mechanical connections have been completed before power is applied This chapter includes discussions of the following topics Powering Up the System e Taking Measurements Using the Display and Keypad WARNING To ensure safe operation of the FGA 300V 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 3 2 Powering Up the System After checking the wiring connections apply power to the analyzer The FGA 300V 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 SCFH IMPORTANT For compliance with the European Union s Low Voltage Directive 73 23 EEC the standard 300V requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be m
118. n Degree 2 For EN 61000 4 3 the FGA 300V X meets Performance Criterion A except at a limited number of frequencies Criterion B per EN 61326 Model FGA 300V X Vertical Gas Analyzer User s Manual 103 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 N gt 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 O 104 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 7 Specifications 7 4 Available Options Some of the available options for the 300V X Flue Gas Analyzer are listed below Remote logarithmic meter e Dual alarm contacts for combustibles Flameproof analyzer CENELEC EEx d IIB T3 ISSEP cert 01E 103 1315 X
119. n the corners of the old FTC board and lift the FTC board out of the enclosure 6 4 2b Installing the New FTC Board 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 1 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 2 Replace the four hex nuts and washers in the corners of the new FTC board and tighten the nuts securely 96 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 4 26 Installing the New FTC Board cont NN 781 Conn TB2 Conn eae AN Fuse FTC Board Standard Weatherproof FTC Box TB1 Conn 2 228889596 al ji BBEEEBEBEEBB Sa ef 8 2 2 el FTC Board TB2 Conn p 2808 6 1S anpa Sm Explosion Proof Flameproof FTC Box Figure 42 FTC Board Location 3 Reconnect the connectors to the 5 pin terminal block TB1 and the 8 pin terminal block TB2 on the new FTC board
120. nalyzer and sampling probe sleeve combination Typically this value will be 80 100 cc min 0 15 0 2 SCFH To set up for calibration complete the following steps 1 Remove the blank plug from the calibration gas inlet port Refer to Figure 23 on page 44 for the location of the calibration inlet port on the Main 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 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 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 IMPORTANT This symbol indicates Caution risk of electric shock AN Model FGA 300V X Vertical Gas Analyzer User s Manual 43 Chapter 4 Calibration 4 3 1 Regulating the Calibration Gas Flow Rate cont Flue Gas Analyzer Series WARNING S
121. nual 85 Chapter 6 Parts Replacement 6 3 56 Installing the New Temperature Sensor 1 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 2 Tighten the clamp to secure the new temperature sensor to the bottom of the sensor furnace 3 Thread the temperature sensor wires to the location of terminal block TB1 in the Main Analyzer Unit 4 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 5 Install the Main Analyzer Unit cover by completing the steps in the Removing the Cover section on page 76 in reverse order 6 Reconnect the main power to the unit and recalibrate the oxygen sensor as described in Chapter 4 Calibration 6 3 6 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 Main Analyzer Unit and is easily replaceable Replacement of the sensor furnace requires the following tools two open end wrenches torque wrench screwdriver digital multimeter CAUTION To replace the sensor furnace the power to the FGA 300V X mu
122. o eeccccccccccco S2 s1 DISPLAY ooo FUEL Figure 21 300D Display 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 32 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 7 2 Setting the Alarm Trigger Mode After setting t
123. 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 Sensing 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 auth
124. ol indicates Caution risk of electric shock AN To check the resistances complete the following steps 1 Locate terminal block TB1 in the Display Console see Figure 25 on page 49 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 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 A 9 IS 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 7 Disconnect the multimeter and immediately reconnect the wire to pin 6 of terminal block TB1 48 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 4 Calibration 4 S3 S2 Sl ALARM ANALOG DISPLAY FUEL n g
125. on requirements of the EN61010 standard Removal of these screws and or components may result in a safety hazard Model FGA 300V X Vertical Gas Analyzer User s Manual 23 Chapter 2 Installation 2 6 4 Making Wiring Connections Wiring for the FGA 300V X involves three steps e Wire the Main Analyzer Unit to the Remote FTC Box e Wire the Display Console to the Remote FTC Box Connect power to the Display Console and the Remote FTC Box Additional connections for optional recorders and alarms are shown later in this section Refer to Appendix D Wiring Diagrams and Circuit Boards or Appendix F Previous Configurations whichever applies to your setup for a wiring diagram of the FGA 300V X WARNING In order to meet CE Mark requirements all cables must installed as described in Appendix F CE Mark Compliance IMPORTANT For compliance with the European Union s Low Voltage Directive 73 23 EEC the standard 300V 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 300VX WARNING To ensure safe operation the FGA 300V X must be installed and operated as described in this manual Also be sure to follow all local s
126. ons 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 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 27 on page 55 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 GS 1 Disconnect the sensor furnace leads from pins 12 and 14 of terminal block TB1 in the Main Analyzer Unit 2 Using a digital multimeter measure the resistance across the disconnected sensor furnace leads One of the conditions listed in Table 14 should occur Table 14 Sensor Furnace Resistance Readings Resistance Reading Recommended Action 63 70 ohms The sensor furnace is good proceed to the FTC board check on page 61 Check the wires from terminal block TB1 to the ceramic block to see if they are broken o
127. or Thermostat Heater Block Cartridge Heaters Figure 2 Sample System Model FGA 300V X Vertical Gas Analyzer User s Manual 3 Chapter 1 General Information 1 2 Description of System cont The FTC Box contains a furnace temperature control board to maintain a constant sensor furnace temperature This temperature stability improves the accuracy of oxygen analysis and extends the life of the oxygen sensor Locate the FTC Box as close to the Main Analyzer Unit as possible as long as the ambient temperatures is 225 to 70 C 13 to 158 F The FTC Box can also be ordered as either a standard weatherproof model or an explosion proof flameproof model as shown in Figure 3 Flue Gas Analyzer L ee Series 300 Standard Weatherproof Model Explosion Proof Flameproof Model Figure 3 FTC Box Enclosures 4 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 1 General Information 1 2 Description of System cont The 300D Display Electronics Console is available for use with the FGA 300V 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 Disp
128. orized 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 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 300V X Vertical Gas Analyzer User s Manual 157 Warranty no content intended for this page 158 Model FGA 300V X Vertical 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 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
129. oxygen sensor and the oxygen sensor clips see Figure 34 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 IMPORTANT Do not remove the oxygen sensor from the sensor furnace at this time 3 While wearing heat resistant gloves slowly unscrew the fitting nut until it is completely free of its fitting Carefully lift the oxygen sensor up and out of the sensor furnace Figure 34 shows an oxygen sensor that has been partially lifted out of the sensor furnace Make sure that the sensor does not hit the sides of the sensor furnace during its removal Inner Clip Outer Clip P Fitting Nut Sensor Body lO Washer Figure 34 Partially Removed Oxygen Sensor 80 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 3b Installing the New Oxygen Sensor 1 Lubricate the threads of the new oxygen sensor GE recommends the use of Molykote High Temperature Non Silicon Lubricant for this purpose 2 When replacing the oxygen sensor handle it only by the fitting at its base Carefully insert the new sensor into the top of t
130. parate boxes The larger box is the Main Analyzer Unit which contains the manifold and the sample system see Figure 8 Flue Gas Analyzer Series WARNING SURFACES ARE VERY HOT Conduit Holes lt a KEEP ANALYZER ENERGIZED Z N lt j WY y Calibration x Gas Port Optional Aspirator Port o A Mounting Flange optional Probe Sleeve Front View Shroud ue Figure 8 Standard Weatherproof Model 10 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 2 2 Standard 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 Oxygen Sensor Convection Loop Sensor Furnace y Combustibles Detector Thermostat Heater Block Cartridge Heaters Figure 9 Standard Sample System Model FGA 300V X Vertical Gas Analyzer User s Manual 11 Chapter 2 Installation 2 2 3 Remote FTC Box The other enclosure is the Remote FTC Box It is mounted separately from the Main Analyzer Unit and contains the furnace temperature control FTC board
131. plugging may be 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 300V X Vertical Gas Analyzer User s Manual 73 Chapter 5 Troubleshooting no content intended for this page 74 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement Chapter 6 Parts Replacement 6 1 Overview The FGA 300V X is designed to enable easy and quick servicing if necessary This chapter describes the replacement of major and minor components of the FGA 300V 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
132. r loose If the wiring is good the sensor furnace is defective and must be replaced refer to Replacing the Sensor Furnace on page 86 open loop OL Model FGA 300V X Vertical Gas Analyzer User s Manual 59 Chapter 5 Troubleshooting 5 2 1d Check the Sensor Furnace cont 3 Reconnect the sensor furnace leads to pins 12 and 14 of terminal block TB1 in the Main Analyzer Unit 4 Complete the action recommended in Table 15 Sensor Furnace Internal Leads Convection Loop Terminal 4p Ceramic Block Figure 29 Top View of Furnace Table 15 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 63 70 ohms inserted Tighten down all four screws and verify continuity across the ceramic block see Figure 29 Check the wires from terminal block TB1 to the ceramic block to see if they are bro open loop OL ken or loose If the wiring is good the sensor furnace is defective and must be replaced refer to Replacing the Sensor Furnace on page 86 60 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 1e 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 blo
133. r s Manual 51 Chapter 5 Troubleshooting Error Indicator Table 9 Troubleshooting Guide System Response Description Go To Possible Oxygen Error Indicators Blinking error code E1 dlarm relay activated analog output shows a lack of oxygen on all ranges Sensor signal exceeds full scale input 1000 possible open circuit possible cold furnace mV Stoichiometric interlock is activated alarm relay activated PPPP and Normal Reading Alternate the sensor signal has not changed in 15 minutes the probe may be plugged sensor impedance is high the sensor may need replacement 1 sensor or its wiring shorted 2 severe air leak i e cal port open sample system not sealed etc sensor wiring reversed Blinking Reading no response Oxygen Concentration Reads Constant 20 996 no response Oxygen Reading Above 20 996 error code E4 or reading of 55 35 Oxygen Reading Too Low no response no response combustibles in the sample Sensor out of calibration poor quality reference air airleak Sensor too cold 4 high sample pressure 1 0 Out Of Range alarms activated combustibles level is greater than 20 000 PPM Indicator 12340 Negative Reading 1 0 Negative Out Of Range Indicator Oxygen Reading Too High no response no response 1 combustibles channel is out of calibration 2 wiring of element reversed 1 refer
134. raction 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 300V X Vertical Gas Analyzer User s Manual Contents Chapter 1 General Information TI PRONTO RUE OU CIL LIE 1 LZ EI eire jl PM T 3 13 Principles OF Operaatio AAA O 6 LSA The Zirc nid ORVAES dl da 6 1 3 2 Platinum Catalyst Combustibles Detector s cac ea aa V neo oce ea ee eg Vota ie da 8 Chapter 2 Installation 21 COUP VIG ts dE ER RUE Gt d dete b pao buco deci t e Aaa Oyen d bx Tiana door 9 2 Physical DescriDHOD ra saan obe ERI EIS eI up a st m alas E qt e payawan ters 10 2 2 1 Standard Weatherproof EncloSute car ar A HAUTE 10 22 2 Standard Sample SU a eae So 11 2 2 5 Remote FIC BOX este cinta deen ee ERA ee sean O e UE Ra
135. rcuitry 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 F2 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 62 on page 144 and complete the following steps IMPORTANT This symbol indicates Caution risk of electric shock AN 3 Using a digital multimeter measure the voltage across pins 5 and 6 on terminal block TB1 in the remote FTC Box NOT on the FTC board If the reading is approximately 80 VAC the FTC board and the transformer are functioning properly If the reading is not approximately 80 VAC proceed to the next step 4 Measure the voltage across pins 10 and 11 on the FTC circuit board NOT on TB1 of the FTC Box If the reading is not approximately line voltage check the main power as there is no power reaching the remote FTC Box If the reading is approximately line voltage proceed to the next step 5 Measure the voltage across pins 8 and 9 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 6 Measure the voltage across pins 6 and 7 on the FTC board transform
136. rd 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 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 64 on page 150 Remove and discard the old transformer Secure the new transformer in place with the four hex nuts and washers that were previously removed SSS 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 If the measured voltage is approximately 80 VAC the new transformer is working properly Close the cover on the remote FTC Box This completes the replacement of the transformer Model FGA 300V X Vertical Gas Analyzer User s Manual 147 Appendix F Previous Configurations F 6 Adjusting the Sensor Furnace Temperature In Chapter 4 Calibration instructions are given for adjusting the operating temperature of the sensor furnace via a poten
137. ribe the steps required to properly set the oxygen and combustibles alarms To set the oxygen alarm Setthe alarm trip point to the desired oxygen percentage Set the oxygen alarm as either a high or low type see page 33 2 7 1 Setting the Oxygen Alarm Trip Point 1 Locate switch S4 on the 300D Display printed circuit board 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 2 Use the following formula to determine the correct analog output trip point I Trip Point O2 9 Trip Point Full Scale O2 96 x 100 3 Adjust switch S4 to the required position refer to the Table 6 and Figure 21 on page 32 For example if an alarm trip point of 6 oxygen is desired with a unit set for a full scale reading of 10 oxygen use 0 the above equation to find the trip point 6096 of full scale range Trip Point 96 t x 100 60 and set 0 Switch S4 to position 6 Table 6 Rotary Switch S4 Settings Alarm Trip Point Switch Position as of Full Scale Range o T 2 3 4 5 6 7 8 9 Model FGA 300V X Vertical Gas Analyzer User s Manual 31 Chapter 2 Installation 2 7 1 Setting the Oxygen Alarm Trip Point cont S4 sS ae AAA ios A l N S3 ALARM N ANALOG No e o
138. rom inside 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 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 300V X Vertical 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
139. s Detector Location 82 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 46 Installing the New Combustibles Detector 1 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 2 Remove the protective plastic cover from the new combustibles detector The two sensing elements on the end of the combustibles detector should not be touched 3 Insert the new combustibles detector into its housing being careful not to damage the two sensing elements and tighten the retaining nut finger tight 4 Orient the new combustibles detector with the active element above the reference element and the serial number label facing out as shown in Figure 36 Using a torque wrench set at 70 N m 600 in lb securely tighten the retaining nut by turning it clockwise as viewed from the end of the combustibles detector Housing Active Element Label Reference Element Retaining Nut Leads Side View Figure 36 Combustibles Detector Orientation 5 Thread the four 4 combustibles detector leads to the location of terminal block TB1 in the Main Analyzer Unit 6 Connect the new combustibles detector leads to the appropriate pins on terminal block TB1 in the Main Analyzer Unit or Accessory Box as follows active element leads to pins 7 and 9 reference elem
140. see Figure 10 The FTC Box can be ordered in either a standard weatherproof or explosion proof flameproof enclosure Flue Gas Analyzer Es saam 2l 300 Standard Weatherproof Model Explosion Proof Flameproof Model Figure 10 FTC Box Enclosures 12 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 2 Installation 2 2 4 Explosion Proof Flameproof Enclosure The explosion proof flameproof FGA 300VX consists of two attached boxes a large Main Analyzer Unit that contains the manifold assembly and the sample system and a smaller Accessory Box mounted behind the Main Analyzer Unit 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 Breather Optional Aspirator Port Flame Arrestor Accessory Box Calibration Gas Port Mounting Flange i Side View N Shroud Probe Sleeve M Figure 11 Explosion Proof Flameproof Model Model FGA 300V X Vertical Gas Analyzer User s Manual 13 Chapter 2 Installation 2 2 Physical Description cont Included as part of the analyzer are the 1 4 NPT probe and the 3 4 NPT probe sleeve The prob
141. site the combustibles detector Trace the four wires from the cartridge heaters to pins 11 2 wires 12 and 14 on terminal block TB1 in the Main Analyzer Unit Disconnect ONLY the cartridge heater wires at pins 11 2 wires 12 and 14 on terminal block TBI IMPORTANT Do not disconnect any of the other leads at these terminals 6 Push on one of the cartridge heaters from the end without the wires while pulling the same cartridge heater out the other side of the heater block 6 3 7b Installing the New Cartridge Heaters 1 Uu o a Um Brush a thin coat of a heat transfer agent on one of the new cartridge heater GE recommends Watlube Heat Transfer and Release Agent Slide the new cartridge heater into the heater block and feed the wires to terminal block TB1 Strip the ends of both cartridge heater wires Repeat steps 6 1 2 and 3 to install the other cartridge heater Connect one wire from each of the cartridge heaters to pin 11 on terminal block TB1 Connect the two remaining wires one from each cartridge heater to pins 12 and 14 on terminal block TBI Install the Main Analyzer Unit cover by completing the steps in the Removing the Cover section on page 76 in reverse order and reconnect the main power to the unit This completes the replacement of the cartridge heaters 92 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 8 Replacing the Thermostat The thermostat whi
142. st 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 6 3 6a 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 300V X 2 Remove the Main Analyzer Unit cover as described in the Removing the Cover section on page 76 3 Disconnect the sensor furnace power wires from TBI pins 12 and 14 in the Main Analyzer Unit 4 Remove the temperature sensor located on the bottom of the sensor furnace as described in the Replacing the Temperature Sensor section on page 84 Place the temperature sensor aside for later reinstallation 86 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 6 Parts Replacement 6 3 6a Removing the Old Sensor Furnace cont Side View Top Wrench Top Wrench Bottom Wrench 1 Bottom Wrench Bottom Wrench Sensor Furnace 2 f EN n i gt 3 Bottom View Top Wrench Convection Loop Figure 38 Wrench Positions 5 Place one open end wrench on the flat surface machined into the piping just below the sensor furnace Place a secon
143. tance approximately full line voltage voltage greater than 0 The FTC board is defective and must be replaced See Chapter 6 Parts but less than full line voltage Replacement 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 30 on page 61 for the location of TB1 One of the conditions listed in Table 17 should occur Table 17 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 30 on page 61 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 If the display continues to blink contact the factory for assistance Note Older FGA 300V X analyzers may have a different FTC board and or a sensor furnace power transformer For units so equipped refer to Appendix F Previous Configurations for troubleshooting instructions 5 2 2 PP PP and Normal Reading Alternate This oxygen display condition indicates that the si
144. the operating temperature of the sensor furnace A standard FGA 300V X operates at a temperature of either 770 C or 812 C Table 11 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 measured value 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 W C 0 385 Model FGA 300V X Vertical Gas Analyzer User s Manual Chapter 5 Troubleshooting 5 2 16 Check the Temperature Sensor cont Checking Units with a Thermocouple Temperature Sensor 1 Locate the Main Analyzer Unit TC leads at pins 3 and 4 of terminal block TB1 in the Remote FTC Box 2 Using a digital multimeter measure the voltage across the TC terminals One of the conditions listed in Table 12 should occur 3 Complete the action recommended in Table 12 Table 12 TC Voltage Readings Voltage Reading Recommended Action about 30 33 mV 770 C or The temperature is good about 32 35 mV 812 C proceed to the oxygen sensor check on page 59 about 0 3 5 mV The temperature is low either 770 C or 812 C proceed to the sensor furnace check on page 59 0 mV reading The TC is def
145. tiometer 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 62 on page 144 The calibration instructions are otherwise identical F 7 Previous Wiring Diagrams and Circuit Boards The following drawings are included for reference to previous versions of the FGA 300V X They include e FTC Circuit Board layout Wiring Diagram with transformer Display Circuit Board layout 148 Model FGA 300V x Vertical Gas Analyzer User s Manual Appendix F Previous Configurations AA a lll l l l l l ll l l ll l l lll ll ll lll l Cl ll lC l il iii i est 1 83WHOJSNV3 L N YINYOJSNVSL NI DVA 08 NI 2VA 08 12 pin Connector plugs into TB1 JOVNYNS JOVNYNS LVLSOWYSHL aly aly 1703 929
146. tion 3 4 Using the Display and Keypad 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 Hs 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 7 along with their corresponding keys All of the parameters listed in Table 7 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 Appendix A page 113 for more details Table 7 FGA 300V X Keypad Parameters Key Parameter Description This parameter with respect to the total flue gas volume supplements Equivalent Combustibles opine 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 con
147. to proceed to the appropriate section to perform the calibration properly WARNING To ensure safe operation of the FGA 300V 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 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 N3 calibration gas for oxygen sensor all ranges b zero gas for combustibles c this gas should read 32 1 mV at 770 C 1 292 FP or 33 4 mV at 812 C 1 494 F Note This gas must be combustibles free even if the analyzer is not fitted with a combustibles detector 2 1000 PPMV CO 500 PPMV H 1 O2 Balance No a span gas for combustibles b this mixture should read 1500 ppm combustibles Note The presence of the 1500 ppm combustibles will cause the O gt to read low by 750 ppm Model FGA 300V X Vertical Gas Analyzer User s Manual 41 Chapter 4 Calibration 4 2 Recommended Calibration Gases cont IMPORTANT A calibration gas containing only CO is not recommended since the analyzer will not respond correctly to dry calibration gases that do not contain Ho IMPORTANT The gas cylinders must be certified as to the exa
148. ture Sensor If the FGA 300V X is fitted with an RTD temperature sensor follow the steps listed below If the FGA 300V X is fitted with an optional thermocouple TC temperature sensor follow the steps on page 57 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 Checking Units with an RTD Temperature Sensor 1 Disconnect the Main Analyzer Unit RTD leads from pins 3 and 4 of terminal block TB1 in the Remote FTC Box 2 Using a digital multimeter measure the resistance across the disconnected RTD leads One of the conditions listed in Table 10 on page 56 should occur 3 Complete the action recommended in Table 10 on page 56 Model FGA 300V X Vertical Gas Analyzer User s Manual 55 56 Chapter 5 Troubleshooting 5 2 16 Check the Temperature Sensor cont Table 10 RTD Resistance Readings Resistance Reading Recommended Action about 365 385 ohms 770 C or The temperature is good about 375 395 ohms 812 C about 105 140 ohms either 770 C or 812 C open loop OL either 770 C or 812 C proceed to the oxygen sensor check on page 59 The temperature is low proceed to the sensor furnace check on page 59 The RTD is defective and must be replaced see Replacing the Temperature Sensor on page 84 Note Ifa resistance reading other than those listed above is obtained refer to Table 11 to determine
149. u A OE A AAA oq Eu usa 12 2 2 4 Explosion Proof Flameproof EHCIDSETR c o oderit ies dal o ao edo 13 2S MS TEE 17 2 3 kSelecting Pe SILS Su u a unu sumaya auqa apa aan de e ni SU 17 2 52 AA a A M M A katu me aie 17 24 Preventing Common ODA AS e E da eto a ade ia DEN ua aa uen el 19 2 5 Installing the Probe and Probe Sleeve 19 26 TASTING tbe Syste eed eiit n u manaa UMP SER URGERE OEC Du TEE e hes Touch 21 26 1 Mounting the Analyzer aca u l u uuu T IRI SUI DIU deb Le eee es eae ieee asi 21 2 6 2 Mo nting The Remote FIG Be l uuu using sana res dan 22 2 6 3 Mounting the Display Electronics Console sra ia 23 2 5 Mabimng Wiring t Ope TIODS case s thet us un a Pi seb Ul L a u EE ea da 24 255 ENE CUA RES sc taal as heute nose huis e EE Ep E CEA e id DC cee Ah ce ED ard 30 2 650tonnscibdg AGIS C oce Caro Cs Me tt Cumis leot sect CU u Aaa Cte le o M ET nett te a S 30 2 SOHC ALONE o coL E Cc a ts A OA 31 2451 Setting the Oxygen Alarm Trip POIRE u a a iex NEN Cie ER alee aerate ORA ares oe wa 31 2 7 2 Setting the Alarm Trigger Mode 33 2 7 3 Setting the Combustibles Alarm Trip PAR Cerne eee eres a eot eod a oe e onte 33 28 nstalling Additional Components ss ul un ee soe Re ctis de Oot es ite LA sta oe det reso 34 Chapter 3 Operation Sul OMS VOW kus tiat t etoile qm veto Ra EAR M ow Ea ata a Cp a et ant
150. ut 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 300V X Vertical Gas Analyzer User s Manual 47 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 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 the resistance of the combustibles detector s active and reference elements should measure between 1800 and 1900 ohms 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 symb
151. uy A bc Cree Saa a 90 Sensor Oxygelics z eri eiei E et 1 6 Shroud sya aaah ma eee ae ei wt 14 Site Pr paration iot e tec Dh u a 21 Selection Sea EU RU RC E RO Ug ead 17 Spare Parts List test o h EUER E 99 100 Specifications Combustibles 104 A II de E SN HERE 103 OXVBen cos ead RR al A UA 104 Switches Display Electronics Console 23 Selecting Display Parameter 111 Selecting Fuel Type 111 Model FGA 300V x Vertical Gas Analyzer User s Manual 7 Temperature Heater Black AS a SE 6 Sensor Elrm ade s ios a Ge ERA 6 Sensor TYPE LS u A 55 Thermocouple AREA CHI so as Sak ore V seen pP ae Te uf 84 A 57 Thermostat Replacing 93 Transformer Replacing a o4 dx REA Ree MO EAR 147 TESNE Fis ite y dean e E anda nulo doce ta 143 V Voltage Line Input 16 W Warm Up Time x eer APP A E 37 Warranty adv uyupi kd E EA TR DUE 157 WEEE Directive c duet us fe eee teehee ee iv Wiring See Part Name Model FGA 300V X Vertical Gas Analyzer User s Manua Index 155 Index no content intended for this page 156 Model FGA 300VIX Vertical Gas Analyzer User s Manua 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
152. way from the open end of the probe sleeve see Figure 12 on page 14 WARNING Never allow the flue gas flow to be angled upward and directly into the open end of the probe sleeve 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 1 750 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 in 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 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 ceiling or on top of a horizontal flue duct drill a hole of the proper diameter to accommodate a short length of pipe having at least a 1 875 in 4 8 cm inside diameter A length of 2 in diameter
153. x 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 Analog Output Range 0 596 0 20 mA 0 10 V 0 596 4 20 mA 2 10 V 0 1096 0 20 mA 0 10 V 0 1096 4 20 mA 2 10 V 0 15 0 20 mA 0 10 V 0 1596 4 20 mA 2 10 V 0 2096 0 20 mA 0 10 V 0 20 4 20 mA 2 10 V 0 2596 0 20 mA 0 10 V 0 2596 4 20 mA 2 10 V WO O oO Mm BI WY rN e Use Table 31 to determine the switch S3 setting if switch S2 is set to position 3 Table 31 Switch S3 Settings S2 3 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 Model FGA 300V X Vertical Gas Analyzer User s Manual 115 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 Setting the scale type zero based or offset Setting the
154. y reading or Turn R105 counterclockwise to reduce the ppmy reading This completes the calibration of the combustibles detector 50 Model FGA 300V x Vertical Gas Analyzer User s Manual Chapter 5 Troubleshooting Chapter 5 Troubleshooting 5 1 Overview The FGA 300V 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 300V 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 9 on page 52 to troubleshoot the FGA 300V X analyzer WARNING To ensure safe operation of the FGA 300V 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 300V X Vertical Gas Analyzer Use
155. zAjouy uow 69 9 1 11812 919 Uu T JO WO T WYO 1 suondo yyBua A s Y eqoJd Duiqm 17 T 0 9 SIU IV je u SOD uonpJqip jpuondo 3ejuj 401DJids 1 l ul Aly oung e ueJejey Proof Flameproof Ion Explos it 1 of 2 in Analyzer Un igure 47 Ma F 121 Model FGA 300V X Vertical Gas Analyzer User s Manual Appendix B Outline and Mounting Dimensions SYIdd3d NVEZT 78 SVE JIdAL YSIYYVE YO S43dd3d N792T D06 SVE GYVGNVLS SGNV19 3189 NO Y OT S8 X3INI YO OZNOSIGNO4 N8SZ OT 868 X3INI 31ddl LINGNOD OZNOSIGNOS X979 01 78 X3INI YO WWW 20 98 QV 1539 9 NMOHS LON NOILVINSNI 38813 1V393 Ue t HLIM 3GISNI NO G3SLVINSNI 38 9E2T SOT 096 d3SSI 9200027 0NI 796 01 216 8 U 0T 28 X3INI 220022 TO IND OZ n8 0L 01226 d3SSI 2200827 IND WY n8 0T 01226 d3SSI 220091 2 809 WYW 30 3NO 33 150 10N3 WNIWYSL SOI DIP X33 n2 0T 012 6 d3SSI 06019 SA 13 WYW 3 A1V 831V338 YOLSJYYY 3lAV 13 1V0283Q Od O38N1X31 HSINI3 7 318V1 S NOILO3S 766T 8T00S N3 SNYNL S 39v9N3 OL SOVISHL IAN 9NILV S 3825 8145 S32IA30 DNIADO1 YO 1NV1V3S QV33HL ONISN 03907 38 OL SLNIOF 319W1 S NOLLO3S 766T 8T00S NI WUB SNYNL S 30 WAWINIW V 32v9N3 OL SOVISH WNIOIN S96 8 T S96 OSI 38 OL SQv38H L d3rlddns WOY 03413938 SV ASN GALLIWYSd ONINIHDVW TVNOI 180 INN IV 11

FGA 300V(X) Vertical Flue Gas Analyzer User`s Manual

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