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GE CGA 351 User Manual

Zirconia oxygen analyzer
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GE Infrastructure
Sensing
Model CGA 351
Zirconia Oxygen Analyzer
User's Manual
910-199C
December 2004
The Model CGA 351 is a GE Panametrics product. GE Panametrics has joined other GE high-technology
sensing businesses under a new name—GE Infrastructure Sensing.
www.DataSheet4U.com

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Summary of Contents for GE CGA 351

  • Page 1 GE Infrastructure Sensing Model CGA 351 Zirconia Oxygen Analyzer User’s Manual 910-199C December 2004 The Model CGA 351 is a GE Panametrics product. GE Panametrics has joined other GE high-technology sensing businesses under a new name—GE Infrastructure Sensing. www.DataSheet4U.com...
  • Page 2 If a GE Infrastructure Sensing, Inc. instrument malfunctions within the warranty period, the following procedure must be completed: 1. Notify GE Infrastructure Sensing, Inc., giving full details of the problem, and provide the model number and serial number of the instrument.

  • Page 3: Table Of Contents

    Mounting the Model CGA 351 ........
  • Page 4 Calibrating the Model CGA 351........
  • Page 5 The Model CGA 351 Nernst Equation ........
  • Page 6 www.DataSheet4U.com December 2004 Table of Contents (cont.) Appendix C: Optional Enclosures Introduction ................C-1 Rack Mount Installation.
  • Page 7 www.DataSheet4U.com Chapter 1 www.DataSheet4U.com...
  • Page 8 www.DataSheet4U.com General Information Introduction........... . 1-1 The Sensor Enclosure .

  • Page 9: Introduction

    This is accomplished with a precision, temperature- controlled, zirconium oxide (zirconia) oxygen sensor. The standard CGA 351 analyzer is supplied in a pair of stainless steel, Nema 4X/IP66 enclosures mounted side-by-side on a metal plate with a 40” flexible conduit connecting the two. This compact, wall- mounted system includes the following components: •...

  • Page 10: Chapter 1: General Information

    www.DataSheet4U.com December 2004 The Sensor Enclosure The sensor enclosure, which is shown in Figure 1-2 below, houses the sample measurement components. The functions of these components are as follows: • a zirconium oxide (zirconia) oxygen sensor converts the oxygen concentration of the sample gas into a mV output signal. •...

  • Page 11: The Sample System

    December 2004 The Sample System In addition to the components supplied with the CGA 351, an external sample system may be required to ensure that the analyzer is fed a properly conditioned sample or calibration gas stream. In particular, the gas must be clean and dry, and it must be delivered to the analyzer at atmospheric pressure.

  • Page 12: Principles Of Operation

    www.DataSheet4U.com December 2004 Principles of Operation A gas sample is drawn into the inlet port of the analyzer by gas diffusion and a gentle convective flow. The sample gas then flows through a ceramic inlet tube and into the annular space between the inlet tube and the inside of the zirconia oxygen sensor.

  • Page 13: The Zirconia Oxygen Sensor

    www.DataSheet4U.com December 2004 The Zirconia Oxygen The inside and outside of the zirconia oxygen sensor are coated with Sensor porous platinum, forming two electrodes. The sample gas flows past the inside of the sensor, while atmospheric air circulates freely on the outside of the sensor.

  • Page 14: The Heater Control Circuit

    December 2004 The Heater Control The oxygen sensor temperature in the CGA 351 is maintained by a Circuit heater, which is part of a complex temperature control loop. This circuit constantly monitors the oxygen sensor temperature, compares it to the set point temperature (700°C), and turns the heater ON or OFF accordingly.
  • Page 15 www.DataSheet4U.com Chapter 2 www.DataSheet4U.com...
  • Page 16 Mounting the Model CGA 351 ........

  • Page 17: Introduction

    –25 to +50°C (–13 to +122°F) specified for the instrument. !WARNING! To ensure safe operation of the CGA 351, 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.

  • Page 18: Choosing An Installation Site

    Site with a GE Infrastructure Sensing applications engineer or field sales person at the time the CGA 351 was ordered. Thus, the equipment should be suited to the application and the planned installation site. Before installing the unit, however, read the following guidelines to verify that the best installation site has been chosen for optimum instrument accuracy and reliability.

  • Page 19: Mounting The Model Cga 351

    IMPORTANT: For compliance with the European Union’s Low Voltage Directive (73/23/EEC), the CGA 351 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.

  • Page 20: Connecting The Sample System

    System sample at a flow rate of 1,000 ±150 cc/min. For best results, mount the sample system as close as possible to the CGA 351. An ideal location would be on the same panel, just below the analyzer. If there are questions, consult with an applications engineer at GE Infrastructure Sensing.

  • Page 21: Wiring The Analyzer

    1.8 m (6 ft) of the unit. !WARNING! To ensure safe operation of the CGA 351, 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.

  • Page 22: Wiring The Outputs (Tb1)

    Connect the output wire from the alarm-1 device to pin c. If desired, repeat sub-steps a and b to connect alarm-2. 5. Connect any shields to pin Proceed to the next section to continue wiring the CGA 351. www.DataSheet4U.com Installation...

  • Page 23: Wiring The Inputs (Tb2)

    December 2004 Wiring the Inputs (TB2) Terminal block TB2 contains connections for the CGA 351’s sample measurement signals. Specifically, the following signals are routed to this terminal block: • zirconia oxygen sensor • thermocouple • sensor furnace All of the connections on terminal block TB2 have already been wired at the factory.

  • Page 24: Wiring The Line Power (Tb3)

    Wiring the Line Power Terminal block TB3 contains connections for the line power to the (TB3) CGA 351. To wire the line power, complete the following steps: !WARNING! Before proceeding with the section, verify that the line power has been turned off at the external disconnect device.
  • Page 25 November 2003 Installation...
  • Page 26 November 2003 Installation 2-10...
  • Page 27 www.DataSheet4U.com Chapter 3 www.DataSheet4U.com...
  • Page 28 www.DataSheet4U.com Operation Introduction........... . 3-1 Preventing Common Problems .

  • Page 29: Chapter 3: Operation

    In addition, be sure to follow all applicable local safety codes and regulations for installing electrical equipment. Preventing Common Use the CGA 351 to accurately measure low oxygen levels. To avoid Problems problems, observe the following: •...

  • Page 30: Powering Up The System

    1.8 m (6 ft) of the unit. User Program Security The CGA 351 has been equipped with a User Program that permits the setup and calibration of the instrument for optimum performance in any specific application. However, to prevent accidental changes to critical system parameters, four levels of security are imposed on the various submenus within the User Program.

  • Page 31: Configuring The Digital Display

    www.DataSheet4U.com December 2004 Configuring the Digital The digital display panel at the top of the electronics enclosure Display includes the components shown in Figure 3-1 below. Display Window Cursor Control Keypad POWER Button ESC Button ENTER Button Figure 3-1: Digital Display Panel A typical display will be configured to the customer’s needs at the factory.

  • Page 32: Initial Screen Displays

    www.DataSheet4U.com December 2004 Initial Screen Displays Immediately upon power up, the digital display shows the following sequence of informational screens, as the meter performs its internal systems checks. BSeries Loader v1.05 This is a typical example of the first initialization screen. Boot is Flash.

  • Page 33: Configuration Options

    www.DataSheet4U.com December 2004 Configuration Options Disp Upon entering the User Pro- [Cfg] gram, the option is already selected. Simply press [ENTER] [Disp] . (Notice that the option is grayed out at this time. POWER ENTER [1: Cfg] Disp To proceed with the [ENTER] option, press .

  • Page 34: Switching Display Windows

    www.DataSheet4U.com December 2004 Configuration Options Note: The , [2:Alarm-2] [2:Alarm-3] [0:Analog Output] [2:Alarm-1] (cont.) [2:Alarm-4] options are also available in the above box. To select the desired output(s) from the previous list box, complete the following steps: 1. Use the [ ] and [ ] keys to highlight a specific output. For this [0: Display] example, make sure that is selected as one of the...
  • Page 35 www.DataSheet4U.com December 2004 Switching Display Windows (cont.) Disp A list of the available windows is shown. Use the [ ] and [ ] 1: Oxygen pcnt keys to select the desired win- 1: Temperature DegF [ENTER] dow and press 1: Oxygen ppm POWER ENTER [ENTER]...

  • Page 36: Converting Mv To Oxygen Concentration

    See Appendix A, The Nernst Equation, for details on performing such calculations. Powering Down When it becomes necessary to power down the CGA 351 for service, proceed as follows: 1. Press the [POWER] button just below the digital display. 2. Place the external disconnect device into the “OFF” position.
  • Page 37 December 2004 Operation...
  • Page 38 www.DataSheet4U.com Chapter 4 www.DataSheet4U.com...
  • Page 39 Calibrating the Model CGA 351 ........4-31...

  • Page 40: Introduction

    [Disp] option as already being configured.) POWER ENTER As an aid in programming the CGA 351, refer to the menu map, Figure 3-2 on page 3-9. Proceed directly to the appropriate section to www.DataSheet4U.com set up and/or calibrate the analyzer.

  • Page 41: The [Cal] Menu

    Proceed to the appropriate section for specific instructions on the topic of interest. Setting Up the Alarm To set up the CGA 351’s external alarm relays, corresponding to the Relays wiring terminals on TB1, proceed as follows:...

  • Page 42: Setting The Trip Type

    www.DataSheet4U.com December 2004 Setting Up the Alarm Relays (cont.) Alarms Use the [ ] and [ ] keys to select [Alarm-1] and press Alarm-1 [ENTER]. Alarm-2 Alarm-3 POWER ENTER Note: The [Alarm-4] option is also available in the above list box. The following alarm features may be set in this submenu: •...

  • Page 43: Setting The Trip Value

    www.DataSheet4U.com December 2004 Setting the Trip Type (cont.) Alarms A..Trip-Type Use the [ ] and [ ] keys to select the desired trip type, and Above press [ENTER]. Below Above with Fault POWER ENTER Note: The [Below with Fault] option is also available in the above list box.

  • Page 44: Setting The Deadband Value

    www.DataSheet4U.com December 2004 Setting the Deadband Enter the alarm setup menu (see page 4-2) and proceed as follows: Value Alarms..Alarm-Feat Use the [ ] and [ ] keys to select [Deadband Value], and Trip Type press [ENTER]. Trip Value Deadband Value POWER ENTER Note: The [Test] and [Fail-Safe] options are also available in the...

  • Page 45: Testing The Alarm Relays

    www.DataSheet4U.com December 2004 Testing the Alarm Relays Enter the alarm setup menu, as described on page 4-2. To verify that the alarm relay is functioning properly, the alarm may be operated manually as follows: Alarms..Alarm-Feat Use the [ ] and [ ] keys to select [Test], and press Trip Value [ENTER].

  • Page 46: Selecting The Operating Mode

    www.DataSheet4U.com December 2004 Selecting the Operating Enter the alarm setup menu, as described on page 4-2, and proceed as Mode follows: Alarms..Alarm-Feat Use the [ ] and [ ] keys to select [Fail-Safe], and press Deadband Value [ENTER]. Test Fail-Safe POWER ENTER Note: The [Trip Type] and [Trip Value] options are also available in...

  • Page 47: Setting The Temperature Controls

    December 2004 Setting the Temperature To configure the temperature control circuits of the CGA 351, Controls complete the following instructions. Caution! Improper temperature controls settings can seriously degrade the performance of the instrument. Never change these settings without specific instructions from GE Infrastructure Sensing.

  • Page 48: Entering The Setpoint

    www.DataSheet4U.com December 2004 Entering the Setpoint Read the CAUTION! on page 4-8. Enter the temperature control menu as described there and proceed as follows: Temp-Cntrl Use the [ ] and [ ] keys to select [Setpoint] and press Setpoint [ENTER]. Air Offset Prop Band POWER...

  • Page 49: Setting The Air Offset

    Caution! Improper temperature controls settings can seriously degrade the performance of the instrument. Never change these settings without specific instructions from GE Infrastructure Sensing. Enter the temperature control menu, as described on page 4-8, and proceed as follows: Temp-Cntrl Use the [ ] and [ ] keys to...

  • Page 50: Setting The Proportional Band

    Improper temperature controls settings can seriously degrade the performance of the instrument. Never change these settings without specific instructions from GE Infrastructure Sensing. Enter the temperature control menu, as described on page 4-8, and proceed as follows: Note: See page 1-6 for a discussion of the proportional band.

  • Page 51: Setting The Integration Time

    Improper temperature controls settings can seriously degrade the performance of the instrument. Never change these settings without specific instructions from GE Infrastructure Sensing. Enter the temperature control menu, as described on page 4-8, and proceed as follows: Note: See page 1-6 for a discussion of the integration time.

  • Page 52: Setting The Maximum Duty Cycle

    Improper temperature controls settings can seriously degrade the performance of the instrument. Never change these settings without specific instructions from GE Infrastructure Sensing. Enter the temperature control menu, as described on page 4-8, and proceed as follows: Note: The value selected for this parameter indicates the percentage of time that the heater receives power.

  • Page 53: Restoring The Default Values

    IMPORTANT: Restoring the default values invalidates the existing calibration. It will be necessary to recalibrate the meter (see “Calibrating the Model CGA 351” on page 4-31) before reliable readings are obtained. From Temp Control Use the [ ] and [ ] keys to select [Default] and press Int.

  • Page 54: The [Opt-User] Menu

    www.DataSheet4U.com December 2004 The [Opt-User] Menu [Opt-User] After entering the User Program, access the submenu to perform the following operations: • setting the fault alarm type • setting up the analog output • adjusting the display contrast • setting the display backlight •...

  • Page 55: Setting Up The Analog Output

    [ESC] until you exit the User Program or proceed to the appropriate section to continue setting up the user options. Setting Up the Analog To set up the CGA 351’s analog output, enter the User Program (see Output page 4-1) and proceed as follows:...
  • Page 56 www.DataSheet4U.com December 2004 Setting Up the Analog The following procedures may be performed in this submenu: Output (cont.) • Analog Output Type: configure the analog output for a 0-20 mA, 4-20 mA, 0-2 V, or Namur type. • Zero Setpoint: enter the live measurement value that corresponds to the low end of the analog output range.

  • Page 57: Selecting The Analog Output Type

    www.DataSheet4U.com December 2004 Selecting the Analog Enter the analog output setup menu, as described on page 4-16, and Output Type proceed as follows: User Aout Use the [ ] and [ ] keys to [Aout Type] select , and press Aout Type [ENTER] Zero Setpoint...

  • Page 58: Setting The Zero Setpoint

    www.DataSheet4U.com December 2004 Setting the Zero Setpoint Enter the analog output setup menu, as described on page 4-16, and proceed as follows: User Aout Use the [ ] and [ ] keys to [Zero Setpoint] select , and press Aout Type [ENTER] Zero Setpoint Span Setpoint...

  • Page 59: Setting The Span Setpoint

    www.DataSheet4U.com December 2004 Setting the Span Setpoint Enter the analog output setup menu, as described on page 4-16, and proceed as follows: User Aout Use the [ ] and [ ] keys to [Span Setpoint] select , and Aout Type [ENTER] press Zero Setpoint...

  • Page 60: Testing The Analog Output

    www.DataSheet4U.com December 2004 Testing the Analog Output Enter the analog output setup menu, as described on page 4-16, and proceed as follows: User Aout Use the [ ] and [ ] keys to [Test] [ENTER] select , and press Zero Setpoint Span Setpoint Test POWER...

  • Page 61: Setting The Zero Trim

    www.DataSheet4U.com December 2004 Setting the Zero Trim Using the procedure under “Testing the Analog Output” on page 4-21, set the Test Percent to 0. At the analog output setup menu, proceed as follows: User Aout Use the [ ] and [ ] keys to [Zero Trim] select , and press...

  • Page 62: Setting The Span Trim

    www.DataSheet4U.com December 2004 Setting the Span Trim Using the procedure under “Testing the Analog Output” on page 4-21, set the Test Percent to 100. At the analog output setup menu, proceed as follows: User Aout Use the [ ] and [ ] keys to [Span Trim] select , and press...

  • Page 63: Adjusting The Display Contrast

    www.DataSheet4U.com December 2004 Adjusting the Display To adjust the contrast of the LCD display, enter the User Program, as Contrast described on page 4-1, and proceed as follows: Disp Use the [ ] and [ ] keys to [Opt] [ENTER] select and press POWER...

  • Page 64: Setting The Display Backlight

    www.DataSheet4U.com December 2004 Setting the Display To set the LCD display backlight, enter the User Program, as Backlight described on page 4-1, and proceed as follows: Disp Use the [ ] and [ ] keys to [Opt] select . Then, Use the [ ] User [User] and [ ] keys to select...

  • Page 65: Setting Up The Serial Port

    www.DataSheet4U.com December 2004 Setting Up the Serial Port To set up the serial port, enter the User Program, as described on page 4-1, and proceed as follows: Disp Use the [ ] and [ ] keys to [Opt] select . Then, Use the [ ] User [User] and [ ] keys to select...

  • Page 66: Entering The Number Of Data Bits

    www.DataSheet4U.com December 2004 Entering the Number of At the following prompt, enter the number of data bits in each data Data Bits string. Node I..Data-Length Use the [ ] and [ ] keys to select the desired data length [ENTER] and press POWER ENTER...

  • Page 67: Setup And Security Settings

    www.DataSheet4U.com December 2004 Setup and Security [Opt] After entering the User Program, access the submenu to Settings perform the following operations: • setting up the option card slots • setting the security levels Proceed to the appropriate section for specific instructions on the topic of interest.
  • Page 68 www.DataSheet4U.com December 2004 Setting Up the Option Card Slots (cont.) Setup Load-Slot Use the [ ] and [ ] keys to select the desired slot designa- 1: Load [ENTER] tion and press 2: Load POWER ENTER Using a personal computer, enter the appropriate informa- Size: tion.

  • Page 69: Setting The Security Levels

    www.DataSheet4U.com December 2004 Setting the Security Levels To set up the menu security levels, enter the User Program as described on page 4-1 and proceed as follows: Disp Use the [ ] and [ ] keys to [Opt] [ENTER] select and press POWER ENTER...

  • Page 70: Calibrating The Model Cga 351

    December 2004 Calibrating the Model To calibrate the CGA 351 analyzer, the following steps must be CGA 351 completed: • introduce the chosen calibration gas • regulate the calibration gas flow rate • adjust the calibration setting as required Proceed with the instructions in this section to calibrate the analyzer.

  • Page 71: Regulating The Calibration Gas Flow Rate

    See the typical sample system in Figure 1-3 on page 1-3 for an acceptable arrangement. Each CGA 351 is tagged with its optimum calibration gas flow rate, based on the testing performed during its factory calibration. Typically, this value will be 1,000 ± 150 cc/min (2.1 ± 0.3 SCFH).

  • Page 72: Adjusting The Calibration Setting

    December 2004 Adjusting the Calibration After the calibration gas flow to the CGA 351 has been established, as Setting described in the previous sections, the calibration gas setting may be adjusted as necessary. To adjust the heater setting, complete the following steps: 1.
  • Page 73 www.DataSheet4U.com December 2004 Adjusting the Calibration Setting (cont.) Setup Diag Use the [ ] and [ ] keys to [Cal] [ENTER] select and press Slct Cal Menu Item POWER ENTER Setup Diag Use the [ ] and [ ] keys to [Heater] select and press...
  • Page 74 4. Discontinue the flow of calibration gas to the analyzer. 5. Resume the flow of process gas to the analyzer. 6. If necessary, reconfigure the digital display to show the desired process parameter. The CGA 351 may now be placed back into service. www.DataSheet4U.com Setup and Calibration 4-35...

  • Page 75: Checking The Current Settings

    December 2004 Checking the Current To aid in monitoring the operation of the CGA 351, a built-in Settings diagnostics routine is included in the User Program. To access this submenu, proceed as follows: [ESC] 1 Oxygen Press to access the User Program (see page 4-1).

  • Page 76: Checking The Sensor Impedance

    www.DataSheet4U.com December 2004 Checking the Sensor Enter the [Diag] as described on page 4-36, and proceed as follows: Impedance Setup Diag Use the [ ] and [ ] keys to [Impedance] select and press Impedance [ENTER] View Temp Controls POWER ENTER Sensor-Impedance The oxygen sensor impedance,...

  • Page 77: Www.datasheet4U.com

    www.DataSheet4U.com Chapter 5 www.DataSheet4U.com...
  • Page 78 www.DataSheet4U.com Service and Maintenance Introduction........... . 5-1 General Troubleshooting .

  • Page 79: Chapter 5: Service And Maintenance

    If a faulty component is discovered in the CGA 351, that component is usually replaceable on site. Contact the factory to obtain a new part, and proceed to the appropriate section of this chapter for installation instructions.

  • Page 80: Checking The Wiring

    www.DataSheet4U.com December 2004 Checking the 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. IMPORTANT: These symbols indicate Caution - dangerously hot surfaces and risk of electric shock, respectively: 1.
  • Page 81 December 2004 Checking the To check the thermocouple temperature sensor used in the CGA 351, Thermocouple complete the following steps: !WARNING! There are very hot surfaces in the sensor enclosure. Touching any of these surfaces without heat resistant gloves will result in serious burns.

  • Page 82: Checking The Thermocouple

    www.DataSheet4U.com December 2004 Checking the Thermocouple (cont.) 1000 1100 1200 TEMPERATURE (°C) Figure 5-1: TC Voltage vs. Temperature Table 5-2: TC Voltage vs. Temperature E( mV) E( mV) Temp.(°C) Temp.(°C) (0.7981) 29.5841 19.8462 30.0002 21.9783 30.4153 24.1073 30.8296 24.5322 31.2429 24.9566 31.6553 25.3805...

  • Page 83: Checking The Oxygen Sensor

    www.DataSheet4U.com December 2004 Checking the Oxygen If the thermocouple voltage was within the normal range, the Sensor troubleshooting sequence should continue here. Note: For information regarding component locations and/or wiring connections in an optional enclosure, see Appendix C. 1. Disconnect the oxygen sensor ( ) leads (white ) from terminal block...

  • Page 84: Checking The Sensor Furnace

    www.DataSheet4U.com December 2004 Checking the Sensor If the sensor furnace impedance test indicated that the sensor furnace Furnace Voltage is good, continue the troubleshooting procedure here. Note: For information regarding component locations and/or wiring connections in an optional enclosure, see Appendix C. 1.

  • Page 85: Oxygen Measurement Errors

    www.DataSheet4U.com December 2004 Oxygen Measurement This section discusses each of the following possible oxygen errors: Errors • oxygen concentration stuck at 20.93% • oxygen concentration reading above 100% • oxygen reading too low • oxygen reading too high Refer to the appropriate section of this chapter and to Figure 5-2 on page 5-25 for help in troubleshooting each of the above situations.
  • Page 86 www.DataSheet4U.com December 2004 Checking for Plumbing A plumbing leak permits cross-contamination of the reference air and Leaks the sample gas. Use the following steps to remedy the problem: 1. Make sure that the calibration gas port in the sample system has not been left open.

  • Page 87: Oxygen Reading Above 100

    www.DataSheet4U.com December 2004 Oxygen Reading Above An oxygen display reading greater than 100% is almost always 100% caused by reversed wiring of the oxygen sensor. For example, 4% oxygen at 700°C would generate an oxygen sensor output of +34.69 mV. However, reversed oxygen sensor wiring would cause this reading to be –34.69 mV.
  • Page 88 Proceed as follows: • The easiest way to check the sensor temperature is to calibrate the oxygen sensor as described in “Calibrating the Model CGA 351” on page 4-31. The calibration procedure includes instructions for adjusting the sensor furnace temperature, if necessary.

  • Page 89: Calibration Responses

    Calibration Responses Chapter 4, Setup and Calibration, describes the procedures for calibrating the CGA 351 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.

  • Page 90: Parts Replacement

    December 2004 Parts Replacement The CGA 351 is designed to enable easy and quick servicing, if necessary. This section describes the replacement of major and minor components of the analyzer. However, before actually replacing any component, carefully read the complete instructions to become familiar with the procedures.

  • Page 91: The Sensor Enclosure

    www.DataSheet4U.com December 2004 The Sensor Enclosure Those components associated with the oxygen measurement process are located in the sensor enclosure. This section describes the proper procedures for replacing these parts. !WARNING! There are extremely hot surfaces in the sensor enclosure. If these surfaces are touched, serious burns could result.
  • Page 92 7. Reinstall both clips onto the oxygen sensor body. 8. Close the cover on the sensor enclosure. 9. Recalibrate the oxygen sensor as described in “Calibrating the Model CGA 351” on page 4-31. This completes the replacement of the oxygen sensor clips. www.DataSheet4U.com...
  • Page 93 www.DataSheet4U.com December 2004 Replacing the Oxygen The oxygen sensor assembly is mounted beneath the sensor furnace Sensor Assembly and is readily accessible for quick and easy replacement. The following items are needed to replace the oxygen sensor: IMPORTANT: For proper operation in the low ranges, the oxygen sensor assembly must be replaced as a unit.
  • Page 94 4. Connect the inlet and outlet process fittings to the bottom of the sensor enclosure. 5. Close the cover on the sensor enclosure. 6. Calibrate the new oxygen sensor as described in “Calibrating the Model CGA 351” on page 4-31. This completes the replacement of the oxygen sensor assembly. www.DataSheet4U.com 5-16...
  • Page 95 A standard screwdriver is the only tool needed for replacement of the thermocouple. Complete the following steps, in the order shown, to remove the defective thermocouple: 1. Disconnect the main power to the CGA 351. !WARNING! Failure to cut the main power at the external disconnect device before proceeding will result in serious personal injury.
  • Page 96 6. Close the covers on both enclosures. 7. Energize the main power to the meter and calibrate the oxygen sensor (see “Calibrating the Model CGA 351” on page 4-31). This completes the replacement of the thermocouple. Replacing the Sensor...
  • Page 97 Complete the following steps, in the order given, to remove the old Furnace (cont.) sensor furnace: 1. Disconnect the main power to the CGA 351. !WARNING! Failure to cut the main power at the external disconnect device before proceeding will result in serious personal injury.

  • Page 98: The Electronics Enclosure

    6. Close the cover on the sensor enclosure. 7. Reconnect the main power to the unit and recalibrate the oxygen sensor (see Calibrating the Model CGA 351 on page 4-31). This completes the replacement of the sensor furnace. The Electronics Enclosure...
  • Page 99 4. Install a new fuse of the same type and rating. See Chapter 6, Specifications, for the correct fuse to use. 5. Install the cover on the electronics enclosure, and reapply power to the analyzer. The CGA 351 may now be placed back into service. www.DataSheet4U.com Service and Maintenance 5-21...
  • Page 100 6. Reconnect the main power to the analyzer. 7. Refer to Chapter 3, Operation, and Chapter 4, Setup and Calibration, to reprogram the new digital panel meter. The CGA 351 is now ready to be placed back into service. www.DataSheet4U.com 5-22...
  • Page 101 5. Reconnect the main power to the analyzer. 6. Refer to Chapter 3, Operation, and Chapter 4, Setup and Calibration, to reprogram the new digital panel meter. The CGA 351 is now ready to be placed back into service. www.DataSheet4U.com Service and Maintenance...

  • Page 102: Recommended Spare Parts

    6. Refer to Chapter 3, Operation, and Chapter 4, Setup and Calibration, to reprogram the new digital panel meter. The CGA 351 is now ready to be placed back into service. Recommended Spare Table 5-5: Spare Parts List - CGA 351...
  • Page 103 December 2004 Service and Maintenance 5-25...
  • Page 104 www.DataSheet4U.com Chapter 6 www.DataSheet4U.com...

  • Page 105: Chapter 6: Specifications

    www.DataSheet4U.com Specifications General Specifications......... . . 6-1 Operating Specifications .

  • Page 106: General Specifications

    www.DataSheet4U.com December 2004 General Specifications Accuracy: 0.1 ppm from 0 to 5 ppm ± 2% of reading for all other ranges Repeatability: ± 0.2% of reading Reproducibility: ± 0.2% of reading in 24 hours ± 1% of reading in 30 days Response Time: less than 1 sec for 90% of step change Stability:...

  • Page 107: Operating Specifications

    www.DataSheet4U.com December 2004 Operating Specifications Measuring Range: Any portion of the range: 0.1 ppm – 100% O (field-selectable) Standard Range: 0.1 – 10 ppm O Output Range: 0/4 – 20 mA, 0 – 2 V (digital panel meter output) 0 – 1000 mV (oxygen sensor output) Communications: Standard RS232/RS485 Serial Port Alarm Circuits:...

  • Page 108: Ordering Information

    December 2004 Ordering Information The information below shows how the CGA 351 Analyzer Part Number is configured from the options specified. CGA351- Table 6-1: CGA351 Oxygen Analyzer Ordering Information CATEGORY OPTIONS 1 = 100 VAC 2 = 115 VAC...
  • Page 109 www.DataSheet4U.com Appendix A www.DataSheet4U.com...

  • Page 110: Appendix A: The Nernst Equation

    Equilibrium Conditions ......... . A-1 The Model CGA 351 Nernst Equation ......A-2...
  • Page 111 December 2004 Introduction The CGA 351 zirconia oxygen analyzer uses the Nernst Equation to calculate the oxygen content of the sample 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.
  • Page 112 (A-2) --------------- - 0.049605 T The CGA 351 measures the temperature of the oxygen sensor and automatically inserts the correct value into the Nernst Equation. For example, at the standard oxygen sensor operating temperature of 700°C, Equation A-2 above becomes: 0.2093...
  • Page 113 100% 0.1% 0.01% 0.001% 0.0001% 0.00001% 1,000,000 ppm 100,000 ppm 10,000 ppm 1000 ppm 100 ppm 10 ppm 1 ppm 0.1 ppm Oxygen Concentration Figure A-1: Oxygen Sensor Output at 700°C...
  • Page 114 December 2004 The Model CGA 351 Table A-1: ppm to mV Conversion at 700°C Nernst Equation (cont.) 305.122 229.995 215.757 290.591 229.421 215.463 282.090 228.862 215.174 276.059 228.317 214.889 271.381 227.786 214.608 267.559 227.269 214.330 264.327 226.763 214.056 261.528 226.270...
  • Page 115 www.DataSheet4U.com Appendix B www.DataSheet4U.com...

  • Page 116: Appendix B: Ce Mark Compliance

    www.DataSheet4U.com CE Mark Compliance Overview ............B-1 EMC Compliance.

  • Page 117: Overview

    December 2004 Overview For CE Mark compliance, the CGA 351 zirconia oxygen analyzer must meet both the EMC and LVD directives. IMPORTANT: CE Mark compliance is required only for units used in EEC countries. EMC Compliance For EMC compliance, the electrical connections must be shielded and grounded as shown in Table B-1 below.
  • Page 118 www.DataSheet4U.com Appendix C www.DataSheet4U.com...
  • Page 119 www.DataSheet4U.com Optional Enclosures Introduction........... . C-1 Rack Mount Installation .

  • Page 120: Introduction

    December 2004 Introduction Upon request, the Model CGA 351 analyzer may be supplied in an enclosure other than the standard NEMA-4X enclosures described in Chapter 1 of this manual, General Information. Although the standard installation and wiring instructions set forth in Chapter 2, Installation, will still apply in general terms, some of the details may vary for different enclosure types.

  • Page 121: Connecting The Sample System

    For the best results, the sample system should be mounted as close to System the CGA 351 analyzer as possible. See Figure C-2 below for the location of the Swagelok fittings on the rear panel, and complete the following steps: 1.
  • Page 122 www.DataSheet4U.com December 2004 Connecting the Outputs All of the connections on this terminal block are optional, in that they (cont.) are not required for proper operation of the analyzer. To wire any or all of these output signals, complete the following steps which apply: 1.

  • Page 123: Rack Mount Operation

    Be sure that the input voltage to the CGA 351 complies with the value specified at the time of purchase. To connect line power to the rack mount CGA 351 analyzer, use the power cable supplied with the unit. Plug one end of the cable into the connector on the rear panel and the other end into the power source, then flip the power switch to the “on”...

  • Page 124: Replacing The Fuses

    Chapter 6, Specifications, for the correct fuse to use. 5. Reinsert the fuse holders, making sure the arrows are pointing down, and close the fuse access door. The Rack Mount CGA 351 may now be placed back into service. Fuse Access Door Fuse Holder...
  • Page 125 December 2004 Rack Mount Version...
  • Page 126 December 2004 Rack Mount Version...
  • Page 127 December 2004 Rack Mount Version...
  • Page 128 www.DataSheet4U.com December 2004 Index Alarms Data Bits ......4-27 Deadband Value ..... 4-5 Dead Space .
  • Page 129 www.DataSheet4U.com December 2004 Index (cont.) Heater Parity ......4-27 See Furnace PID Heater Control .
  • Page 130 www.DataSheet4U.com December 2004 Index (cont.) Sample Gas Contamination ....5-9 Temperature Sample System Ambient......2-1 Mounting .
  • Page 131 GE Infrastructure DECLARATION Sensing CONFORMITY Panametrics Limited Shannon Industrial Estate Shannon, County Clare Ireland declare under our sole responsibility that the CGA351 Clean Gas Analyzer CGA350GP Clean Gas Analyzer CGA350X Clean Gas Analyzer CGA350D Display Unit TMO2D Display and Control Unit to which this declaration relates, are in conformity with the following standards: •...
  • Page 132 GE Infrastructure DECLARATION Sensing CONFORMITE Panametrics Limited Nous, Shannon Industrial Estate Shannon, County Clare Ireland déclarons sous notre propre responsabilité que les CGA351 Clean Gas Analyzer CGA350GP Clean Gas Analyzer CGA350X Clean Gas Analyzer CGA350D Display Unit TMO2D Display and Control Unit rélatif á...
  • Page 133 GE Infrastructure KONFORMITÄTS- Sensing ERKLÄRUNG Panametrics Limited Wir, Shannon Industrial Estate Shannon, County Clare Ireland erklären, in alleiniger Verantwortung, daß die Produkte CGA351 Clean Gas Analyzer CGA350GP Clean Gas Analyzer CGA350X Clean Gas Analyzer CGA350D Display Unit TMO2D Display and Control Unit folgende Normen erfüllen:...

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