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E Instruments BTU4400 Industrial Combustion Analyzer User Manual

Contents

1. 40 0 ppm with H2compen sation Electrochemical sensor 0 500 ppm 0 1 ppm 5 measured value 40 1 500 0 ppm 0 diuted Electrochemical sensor 100 3125 ppm 10 ppm 20 measured value co 100 ppm 0 2000 ppm Mid Electrochemical sensor 0 20000 ppm 1 ppm 5 measured value 2001 4000 ppm ic range 10 measured value 4001 20000 ppm diluted e Electrochemical sensor 0 3 12 5 vol 0 01 vol 20 measured value co 0 1 vol 0 2 00 Electrochemic al sensor 0 10 00 vol 0 01 vol 5 measured value 2 01 10 00 f 5 ppm 0 100 ppm Ooo so Oe Electrochemical sensor 0 5000 ppm tem Jet measured Value 101 5000 ppm NO Low range Electrochemical sensor 0 500 ppm 0 1 ppm AE value 40 Y EN oat Pellistor sensor 0 5 00 vol 0 01 vol 0 25 vol 0 0 NDIR sensor 0 40 0 vol 0 1 vol ed vals s T hi Flue gas temperature 100 0 1250 0 C EN a ured value fone esse G 4 1 measured value 10 00 2 01 hPa Piezoel ectric sens or 10 00 200 00 hPa 0 01 hPa 2 Pa 200 200 Pa 1 measured value 2 01 200 00 hPa a a oe C J x arma casa sm o j WNT ENE sas LN WE senm wm oaa NET EN All data relative to concentration accuracies are referred to an instrument operating at a constant temperature within the correct operating range 5 C 45 C being in operation for at least 15 minutes powered by its internal battery and after completion of auto zero procedure Notes 1
2. Configuration software kit USB flash drive PC cable Particulate water filter assembly Particulate water filter assembly with steel pipe and connector Adapter cable USB A mini USB B 8 3 Service Center E Instruments International 172 Middletown Blvd Suite B201 Langhorne PA 19047 USA Tel IST01530EEJ 01 917 5A0 19041 1 215 750 1212 Fax 215 750 1399 E mail Info E Inst com Website http www E Inst com 69
3. Measure Active Limit unit CONDENSATION Altitude R H air Altitude R H air TIME DATE 13 14 12 12 12 EU TIME DATE 03 57 PM 12 12 10 Select the figure to be modified with the keys YA Modify the value of the highlighted figure with keys O The values that can be selected with the w A keysforthis parameter are CO CO ev NO Oz P Tf Ta The values that can be selected with the w A keys forthis parameter are maximum minimum no 25 The alarm threshold values can be set via theyy A keys within the following vee co range Active apes a 99999 999 to 99999 99 L t BSA nit the value is referred to the unit of measurement set maximum minimum no lt The values that can be selected with the Number Number w A keys forthis parameter are Measure Measure A tive A tive Limit Limit ppm mg m mg kWh g GJ glm Punit Unit EE g kWh A Automatic analysis Buzzer Condensation Time Date Alarms gt Buzzer Y w CONFIGURAT ION NOx NO_FACTOR NOx NO_FACTOR NOx NO FACTOR NOx NO FACTOR A Automatic analysis E voo 1 03 gt NOx NO A 03 NOx NO 1 J3 gt NOx NO 1 03 Condensation Time Date Buzzer A gt NOx NO factor Y w Use the EDIT TEXT function as f ollows s gt Condensation Time Date to the box that corresponds to the letter or number required to form the desired word and press to confim
4. When you nave finished striking in the desired text still using the cursor keys go Usingthe A pcursorkeys go Jerry Smith Buzzer NOx NO factor gt Operator Y A lt 9 lt gt IM Z amp Y to to confirm the entered data or to to exit without saving and press the relative Or Ty button The task is done If you wish to modify a letter or a whole line all you need to do is position the cursor in front of the letter to be cancelled by means of the cursor keys in the first row of controls At this point go to the second row of A lt 9 lt gt IM Z amp Y controls and press the key on the dem Smith keypad In this way the etter preceding gt 3 the cursor can be cancelled after which lt 9 AN SHE the desired text can be entered or the user can corfirm and exit A Time Date E Instruments_ Buzzer NOx NO factor A Operator lt 9 lt gt ESE Report header setup Y Y 26 IST01530EEJ 01917 5A0 190411 Philadelphia PA_ A 9 lt gt Z amp p E Instruments T 215 750 1212_ j Philadelphia PA gt 3 T 215 750 1212 A 4 9 lt gt Wg SZ amp P Y REPORT HEADER TEXT EDITING 1 Ej TRStryments info info com_ 2 adelphia PA i Podlage 1212 a gt lt 9 ISSIE TE p r NOx NO factor operator Report header setup gt Micromanometer Y Buzzer pItaliano NOx NO factor English operator Fran
5. a report ticket Ambient CO NO This function allows the operator to easily visualize the peak values of CO and NO in the ambient in order to verify that acceptable safety conditions are present in the ambient before people enter in it It is recommended to respect the concentration limits stated in the following safety standards COmax 35 ppm Recommended exposure limit REL stipulated by the National Institute for Occupational Safety and Health NIOSH equivalent to 40 mg m and calculated as an 8 hour Time Weighted Average TWA NOmax 25 ppm Recommended exposure limit REL stipulated by the National Institute for Occupational Safety and Health NIOSH equivalent to 30 mg m and calculated as an 8 hour Time Weighted Average TWA ATTENTION it is REQUIRED to perform the autozero in the clean air so that the ambient CO and NO measurement are correct It is advisable to turn on the instrument and wait for the autozero completion outside the areawhere the test is being performed preferably OUTSIDE The result of the test can be either associated to the combustion analysis and consequently stored in memory or immediately printed through the Print menu Pressure It is possible through the use of the external flexible pipe made in RAUCLAIR supplied to measure a pressure value within the range stated in the technical features connect the pipe to P input During the pressure measurement the HOLD function is made available w
6. customer demands It may be provided in a rugged ABS carry case or waterproof shoulder bag The instrument contains one single board with all the basic circuitry pre calibrated measuring cells sampling pump membrane keypad backlit graphic LCD display high capacity rechargeable Li lon battery pack and plain paper impact printer The two halves of the case are firmly secured by eight screws on the rear of the instrument The pneumatic path and measuring cells inclusive of electronic micromodule are located on the back side of the plastic case and are easily accessed for maintenance and replacement by removing the cover carrying the functions label The roll of paper is positioned at the upper end on the rear and may be easily replaced by removing the snap on flap The pneumatic connectors for flue gas sampling and pressure draft measurement as well as the flue gas thermocouple connector are installed on the lower end of the instrument On the tight hand side are located the Pt100 combustion air probe and the mini USB connedors On the left hand side there is a plug for connecting the external power supply and an 8 pin min DIN for serial interface or Deprimometer optional The user interface consists of a constantly active backit graphic LCD display and membrane keypad Menu screens and all user messages can be set in the language of the country where it is used this can be selected through the menu in one of the available ones Use of the analyze
7. due to each single pipe section or finally by measuring it through a simple procedure which requires the injection into the piping of a known gas quantity through a graduated syringe In case the volume calculation is used foreach single piping section the Add tube option must be selected and then input the relevant maternal nominal diameter and length 4400 calculates the single section volume and addsit when confirmed to the total piping value For error correction or for modifying the ongoing calculation the subtraction operation is also available 38 IST01530EEJ 01917 5A0 19041 1 When the Volume measurement option is selected instead the procedure described also in the flow charts of the tightness test according to UNI 11137 1 is described in the followng steps e Close both faucets in the kit assembly supplied for the test execution e Connect the graduated syringe to the hose which in the assembly is opposed to the pump e Open the faucet on the side where the syrynge is applied and withdraw exactly 100 ml 100 cc of the gas present in the piping Press the button e Inject the gas present in the syringe back into the piping and then close the faucet again e Wait for the pressure in the piping to stabilize After a few seconds the instrument returns to the volume input screen in which the measured volume is shown The proposed value can be accepted by pressing the e button modified through the arrow keys or rejec
8. wait time 20 00 configuration menu Stabilization can be stopped at P any time by pressing gg Automatically NEW PIPING P1 100 OOhPpa N WARNING P2 99 99hPa End the tightness AP 0 01hPa test Result 15 00 NEW PIPING ABORT ABORT Automatically after 15 minutes 100 OOhPa 99 99hPa 0 01hPa Result tight 41 IST01530EEJ 01917 5A0 190411 New piping pEx1sting piping Selected test is valid for volume pipes up to 25 dm 25 liters It is not y O Tum p to Sei eee required to know and enter the volume of the pipe since it is assumed to Volume calculated Stabilization be 25 dm In this way the leakage rate is actually rounded up and better combustible gas guarantee the validity of a compliant result The test procedure is not described in details because t is the same as the calculated volume shown in thef low chart except f or thev olume size Volume up_to_25dm pStart_ test gt Volume calculated Stabilization Piping volume Combustible gas Test gas w EXISTING PIPING STAB ILI ZAT ION STAB ILI ZAT ION A STAB ILI ZAT ION Start test gt wait time 15 min gt pwait time Hurin W pwait time min e gt Stabi lization Piping volume Combustible gas Test gas w Select the figure to be EXISTING PIPING PIPING VOLUME PIPING VOLUME igi k e modified with the Start test gt gt Vtot 25 0 dm D pVtot 029 0 dms keys q Stabilization 3 gt Piping volume Volume measure Vol
9. 4 17 Measuring the Differential Pressure OPTIONAL HOSE KIT Part AACKP01 The instrument is fitted with an internal temperature compensated piezoresistive transducer to measure positive and negative pressures This sensor which is mounted on the instrument is of the differential type If the speqal KIT is purchased the sensor can be used to measure the differential pressure thanks to the positive and negative pressure connectors The measuring range varies between 1 000 Pa and 10 000 Pa IST01530EEJ 01917 5A0 190411 53 5 0 SENSORS 5 1 Sensors arrangement SENSORS ARRANGEMENT INSIDE GRAPHICAL DISPLAY THE SENSORS COMPART MENT OF ARRANGEMENT CONFIRM FLEX Sensor O2 Cod AAA32 240 FLEX Sensor CO Hz2 Cod AACSE05 FLEX Sensor NO Cod AACSE06 FLEX Sensor NO2 Cod AG526 W00 FLEX Sensor SO2 Cod AD527 W04 FLEX Sensor CO 100 000 Cod AACSE17 FLEX Sensor CO 20 000 Cod AACSE18 FLEX Sensor CO H2 low range Cod AACSE24 FLEX Sensor NO low range Cod AACSE25 FLEX Sensor NO2 low range Cod AACSE26 FLEX Sensor SO2 low range Cod AACSE2 54 IST01530EEJ 01917 5A0 19041 1 5 3 Gas sensor life The gas sensors used in this instrument are electrochemical thus when the relative gas is detected a chemical reaction takes place inside them that generates an electrical current The electrical current acquired by the instrument is then converted into the corresponding gas concentration Sensor life is strongly r
10. 7 Keypad overview On Off Select Modify on ok esc En Memory Menu m lt E Print Menu l Q Zoom IN OUT Configure Menu i Ri FZ Analysis Menu Info Menu WARNING to turn on off the instrument it is necessary to press and hold the On Off button for at least 2 seconds IST01530EEJ 019175A0 190411 17 4 8 Info Menu HE This menu provides information regarding instrument status Battery capacity Shows the status of the internal battery The battery charge status is shown graphically and in text as a percentage between 0 and 100 together with the battery voltage Configuration of sensors It allows to check which sensors are installed on the instrument and in which position they are installed The instrument automatically detects whether a sensor has been either added or removed The screen page allows whether to accept the new configuration or ignore the change performed Sensor diagnostics This feature displays useful information about the status as well as about the calibration of the internal electrochemical sensors Through this screen the user can access the data that fully identify the sensor such as sensor type serial number manufacturing and calibration dates In addition to this are also shown the current values generated by the sensors thus allowing for a quick troubleshooting in case of issues referable to the sensors HW memories diagnostics At instrument tum on the firmwar
11. CO NO amb SAVE test 1 SAVEI Memory Draft SAVE test 2 Smoke CO NO amb SAVEI SAVE test 3 Memory Draft Smoke CO NO amb SAVE Z Eff 83 47 Loss16 67 I Save analysis Save analysis Display average Display average Recall the average test Select memory Select memory values Recall memory Recall memory Delete single Delete single y Y gt ReT02 my pPrint report Print setup Paper feed Print test report pig getup If desired set the preferred number of copies and analysis report format test Print report gt Memory Print setup Analysis 1 1 Paper feed Mode Print the analysis report print test PRINT The system is ready to When printing is complete return tothe Analysis Menu by pressing carry out further tests IST01530EEJ 01 917 5A0 19041 1 51 How to proceed in automatic mode Z Eff 83 47 Z Loss16 67 NO S02 NOx Loss16 67 If when configuring test parameters manual printing has been selected see example the average values will be displayed after the third test values have been read These may be printed by activating the relative menu If onthe other hand automatic printing has been selected the av erage test v alues will be printed automatically Memor 001 Ya Analysis Mode total d total Please wait The system is ready to When printing is complete return tothe Analysis Menu by pressing T carry ou further tests 52 IST01530EEJ 019175A0 190411
12. The maximum CO value displayed depends on the type of fuel 2 Stated predsion indudes error of the extemal sensor RTD Pt100 dass A DIN 43760 1980 3 Stated precision indudes errorof the extemal sensor type K thermocouple class 1 IEC584 4 Pressures greater than 750 hPa may permanently damage sensors or impair their characteristics Pressure draught amp differential 12 IST01530EEJ 019175A0 190411 3 0 USING THE FLUE GAS ANALYZER 3 1 Preliminary operations Remove the instrument from its packing and checkit for damage Make sure that the content corresponds to the items ordered If signs of tampering or damage are noticed notify the E Instruments service center or agent immediately and keep the original packing A label at the rear of the analyzer bears the serial number This serial number should always be stated when requesting technical assistance spare parts or clarification on the product or its use E Instruments maintains an updated database for each and every instrument Before using the instrument for the first time it is recommended to charge the battery for 12 hours with the instrument turned off 3 2 Warnings e Use the instrument with an ambient temperature between 5 and 45 C e When it has finished being used before turning the instrument off remove the probe and let is aspirate ambient clean air for at least 30 seconds to purge the pneumatic path from all traces of fumes e Do not use the instrument if t
13. ais Report header setup Espa o Language Deutsch Y Y Operator Report header setup See MAINTENANCE section Language gt Calibration ISTO1530EEJ 019175A0 190411 27 4 10 Memory Menu m This menu is used to display and print individual and average values of the analysis data stored in memory Analysis data can be ordered either by memory position or by storage date draft and smoke values can also be recalled The Print Menu is enabled in both the analysis screen and draft and smoke level screen within the Recall Memory menu Save analysis This submenu displays the current active MEMORY and the data stored within and allows the user to record new values or to overwrite them if these are already present and complete Display average Displays the average of the analysis data stored in the active memory Select memory Allows the user to select the memory within which to record any effected analyses or other data such as draft smoke and ambient CO NO values When the menu is accessed a preview of all saved data will appear Recall memory This menu just like the previous one lets the memory be selected on the basis of the stored position or storage date thereby letting all stored data be displayed individual and average readings draft smoke and ambient CO NO values Delete single Allows the user to erase the data stored for a single memory A oonfirmation is required in order to avoid an accid
14. be measured using the air temperature probe since the internal sensor might lie at a different temperature with respect to ambient ISTO1530EEJ 01917 5A0 190411 13 ATTENTION THE POWER SUPPLY BATTERY CHARGER IS A SWITCHING TYPE ONE THE APPLICABLE INPUT VOLTAGE RANGES BETWEEN 90Vac AND 264Vac INPUT FREQUENCY 50 60Hz THE LOW VOLTAGE OUTPUTIS 12 VOLT WITH AN OUTPUT CURRENT GREATER THAN 1 5A LOW VOLTAGE SUPPLY CONNECTOR DC PLUG 2 1x5 5x9 mm WITH CENTRAL POSITIVE AND OUTER BARREL GROUND IF AN UNSUITABLE POWER SUPPLY IS CONNECTED IT CAN DAMAGE THE INSTRUMENT USE ONLY THE ONE SUPPLIED WITH IT IST01530EEJ 01917 5A0 19041 1 4 0 OPERATION 4 1 Working principle The gas sample is taken in through the sample probe by a diaphragm suction pump inside the instrument The measuring probe has a sliding cone that allows the probe to be inserted in holes with a diameter of 11 mm to 16 mm and to adjust the immersion depth the sampling point must be roughly in the center of the flue pipe stack The gas sample is cleaned of humidity and impurities by a condensate trap and filter positioned along the rubber hose that connects the probe to the analyzer The gas components are then analyzed by the electrochemical sensors Oxygen O2 is measured with an electrochemical cell that acts like a battery which over time is apt to lose sensitivity The toxic gases CO SO2 NO NO2 are measured with electrochemical sensors that are no
15. choosing among different lay outs according to the informations Copies 1 Copies 1 Copies 1 included gt Model gt Model gt Model Print report Analysis running Print setup full Paper feed Print test Please wait According to the values shown on the display when the menu is activ ated and the selected ticket layout the user can choose among different models In the examples are reported the cases of Memory Analysis 1 printing the analysis under acquisition Mode printing a single analysis after recall from Please wait memory and printing an average analysis after recall from memory Go ahead for printing is given by pressing j with the PRINT option highlighted in PRINT REPORT PRINT REPORT the packground Memory 001 Memory 001 Analysis average Analysis average Mode full Mode full Please wait PRINT QUIT report setu eed Paper feed Paper feed test START Print report Print setup Report test print Report test print Paper fee pPrint test Please wait START QUIT ISTO1530EEJ 01917 5A0 190411 4 12 Analysis Menu Through this key the analysis results are displayed Moreover the operator is allowed once this key is further depressed to display and possibly modify the analysis parameters before proceeding with the measurements Measuredvalues are O2 Oxygen percentage in the Flue CO H2 CO concentration in the Rue CO H2 low range CO concentration in the Hue with 0
16. cursor keys w A To cancel changes and return to the prev ious menu press ER gt Natural gas 2 Oi Measurement units Oz Reference 4 O11 Display contrast Diesel Autozero Pump wood Pel lets Y Y w w FUEL Natural gas gt 2 Oil 4 O11 Diesel wood Pellets Y 0 0305 0 0066 15 70 42900 kJ kg 45700 kJ kg Natural gas 2 Oi i gt 4 Oil te Diesel wood Pel lets Y PARAMETERS 0 0305 0 0066 15 70 42900 kJ kg 45700 kJ kg Wood pellets Y FUEL Natural gas 2 Oi 4 Oi Diese pwood Pellets Y a 2 Oi 4 oil Diesel wood Pel lets gt Coal A 4 Oi 0 0305 Diesel B 0 0066 Wood Pellets ia 15 70 oa PBiO RUEN 5 426000 Keg FUEL A Diesel wood Pel lets 0 0073 13 80 46180 kJ kg Coa Bio Fuel 5 Fa 50110 kJ kg PL P G lt 22 IST01530EEJ 019175A0 190411 A wood Pellets 8 oa Bio Fuel 5 L P G gt Butane Y Coal Bio Fuel 5 L P G Butane gt Propane CONF IGURAT ION MEASUREMENT_UNITS Fuel ppm pMeasurement units NO NO2 NOX ppm 02 Reference Pressure hPa Display contrast Temperature c Autozero Pump v MEASUREMENT UNITS CO ppm NO NO2 NOX ppm Pressure hPa Temperature CO NO NO2 NOX ppm Pressure hpa gt Temperature c CONFIGURATION O2 REFERENCE gt CO 0 0 NO NO2 NOx 0 0 Fuel Measurement units DO Reference Display contrast Autozero Pump Y av Co 0 0 gt NO NO2 NOX 0 0 IST01
17. data analyses time and name of the customer can be stored User data 3 programmable user names Print out heading 4 lines x 24 characters customisable by the user Display Graphic backlit LCD measuring 42 x60 mm Communication port USB with mini USB connector Line filter With replaceable cartridge 99 efficient wth 20um partides Suction pump 1 2 min heads atthe flue up to 135hPa Condensate trap Outside the instrument Carbon black Using an optional external Smoke hand pump it is possible to simply enter and print the Smoke index results Leak test Gas pipes tested for leaks with separate printout of the result by means of the attachment AACKT02 according to UNI 7129 new systems and UNI 11137 1 existing systems with automatic calculation of pipe volume Condensing boiler efficiency Automatic recognition of the condensing boiler with calculation and printout of efficiency gt 100 on the LHV Lower Heating Value in accordance with UNI10389 1 Environmental gases Measurement and separate printout of the ambient CO and NO values Draft test Draft tested as per the UNI 10845 standard Using the external draft gauge AACDP02 the resolution is 0 1 Pa wth 0 5 Pa accuracy Operating temperature range 5 C to 45 C Storage temperature range 20 C to 50 C Operating humidity range 20 to 80 RH Protection grade IP42 Air pressure Atmospheric Outer dimensions Analyzer 30 7 x 10 5 x 9 6 com W x Hx D Cas
18. issue calibration certificates When the cells are flat they can be replaced easily by the user without having to send the instrument away and without complicated calibration procedures requiring sample mixtures as they are supplied already calibrated E Instruments does however certify measurement accuracy only when a calibration certificate has been issued by its own laboratory or by an authorized laboratory Temperature sensors Flue gas temperature is measured by means of a thermocouple inserted in the tip of the probe The thermocouple is connected to the instrument via a compensated cable pos Q in Fig 2 2 housed in a special seating in the rubber hose of the sample probe Connection to the instrument is achieved via a temperature compensated male connector IST01530EEJ 01917 5A0 19041 1 9 The cold junction is compensated by a Pt 100 resistance thermometer which measures the temperature at the thermocouple connedor The type K themocouple nickel nickel chromium permits continuous measurements up to 800 C If special purpose probes are used the instrument is able to measure temperatures as high as 999 9 C A Pt 100 resistance thermometer located inside the instrument measures the internal temperature this sensor is also used to measure the ambient temperature Should the user want to measure the combustion air temperature directly in the intake duct the optional remote Pt 100 sensor must be used this measurement is
19. makes it possible to comply with the UNI 10845 standard Burner pressure verification probe It must be used to measure burner pressure of the gas powered boiler so it can be regulated in real time It is made of a silicone tube 8x4mm and 1 metre long complete with connector for connecting to the analyzer Probe for measuring the ionization current With this special probe itis possible to measure the ionization current of a boiler and check its value depending on the boilers technical features Calibration certificate The instrument is calibrated by comparing to National Calibration Standards provided by a Metrology Lab certified periodically by internationally recognized laboratories A calibration certificate is provided wth each and every instrument where every parameter is accompanied by the relevant nominal value measured value permissible error tolerances and measured error Electromagnetic compatibility The instrument was designed to comply wth Council Directive 2004 108 EC governing electromagnetic compatibility ISTO1530EEJ 019175A0 190411 11 2 3 Measurement Ranges and Accuracies fF Oe Electrochemical sensor 0 25 0 vol 0 1 vol 0 2 vol co 10 ppm 0 200 ppm ith H ti Electrochemic al sensor 0 8000 ppm 1ppm 5 measured value 201 2000 ppm ee compen aon 10 measured value 2001 8000 ppm diuted e Electrochemical sensor 0 15 5 00 vol 0 01 vol 20 meas ured value CO Low range i 2 ppm 0
20. mode is selected define the test time and print mode automatic or manual 35 443 Draft Menu gq The DRAFT menu gives access to the stack draft measurement The user to input the extemal air temperature as required by the standard Afterwards the measurement screen is reached here the user can acquire the value displayed in order to add it to the running analysis measurements or alternatively print the relevant ticket through the PRINT menu NOTE The measurement may not be accurate due to condensation inside the sample probe Should you notice an inaccurate or unstable reading on the instrument it is advisable to disconnect the sample probe from the instrument itself and purge pipes by blowing with a compressor In order to be sure there is no humidity it is suggested to perform the measurement by means of the transparent rubber pipe supplied on issue 4 13 1 Flow Chart Draft Menu Q g Activ ates the Draft Menu us P negative Connect the probe pressure input hose to the instrument P input Inlet 0 00hPa Before starting the pressure zeroing sequence pay attention to remove the gas probefrom the stack Pressure zeroing is accomplished by pressing withthe ZERO option highlighted in the background Insert the probe in the stack and measure the draft In order to add the draft value to those of the ongoing analysis please select KEEP through the R right arrow key then press For a printout of gt Pr
21. recommended for more pred se calculation of plant efficiency Remote temperature probe The temperature probe consists of a Pt 100 probe complete with 2 m cable and 7 5 17 mm pit adapter pos in Fig 2 2 This probe is used to measure the combustion air temperature within a range of 10 C to 100 C when boiler effidency is to be calculated precisely Pressure sensor The instrument features an internal piezoresistive sensor to measure the stack draft negative pressure and other parameters if required gas network pressure pressure drop across filters etc The user can switch from flue gas analysis to this reading by simply pressing a key Sample and pressure inputs Pos in Fig 2 2 is the input of the sample probe complete with water separator and particulate filter Po and in Fig 2 2 are respectively the positive and negative internal differential pressure sensor inputs The positive input P is used to measure pressure in general and for the tightness test The positive input P is used to measure draft in accordance with standard UNI10845 the branch of the fume exhaust probe without the anti condensation filter should be connected to it for simultaneous draft measurement and combustion analysis The positive input P and negative input P are used simultaneously to measure differential pressure Fuel types The uie has been programmed with the technical characteristics that are typical of seven common fuels By means o
22. until hearing a dick See point 4 ATTENTION While rotating the sensor take care not to apply any pressure onto the printed circuit above apply pressure onto the plastic body only 9 Reconnect the sensor See point 3 10 Close the back door of the sensor compartment again and tighten screws again See point 1 Tum on theinstrument to check the new sensor works correctly through the menu Sensor Troubleshooting It is normal if a newy installed sensor gives a current error it is necessary to wait some time so that the sensor polarization can settle The table here below shows the minimum settling time for each sensor FLEX Sensor O2 O2 a SETTLING TIME 2 hours FLEX Sensor CO H2 CO Cod AACSE05 Carbon M onox de FLEX Sensor NO NO Cod AACSE06 Nitrogen Oxide FLEX Sensor NO NO2 1 FLEX Sensor SO2 SO2 1 1 S2 s3 48 hours S2 S2 3 2 hours FLEXSensor CO 100 000 CO 2 hours Cod AACSE17 Carbon M onox de FLEX Sensor CO 20 000 CO Cod AACSE18 Carbon M onox de FLEX Sensor CO H2 co low range Carbon M onox de 2 2 hours Cod AACSE24 FLEX Sensor NO NO low range Saa s 48 hours Cod AACSE25 FLEX Sensor NO2 NO low range TOER n pA S3 S4 2 hours Cod AACSE26 oF FLEX Sensor SO2 so low range dishar ad 3 S4 2 hours Cod AACSE28 Note 1 2 Hour settling time is required 2 48 Hour settling time is required should the sensor be equipped with an extemal polarisation battery t
23. 0 TROUBLESHOOTING SYMPTOM PROBABLE CAUSES AND REMEDIES The instrument does not work at all When the On Offla Keep the On Off key depressed for at least 2 pushbutton is pressed the instrument does not come seconds b The battery is low connect the battery charger to the instrument c The battery packis not connected to the instrument remove the cover from the battery compartment and connect the connector of the battery pack to the outlet on the printed drcuit board d The instrumentis faulty send it to a service center The battery symbol kg is empty on the inside The batteries are low The instrument will remain on for a couple of minutes after which it wil switch off connect the battery charger After auto calibration is complete the sensorja Auto calibration took place while the flue gas was diagnostics screen appears and gives an error for one being sampled or mor cells b The Oz sensor is faulty is not connected correctly or is not connected at all Check the above points also referring to sections 5 6 5 7 58 c The sensor was not allowed the necessary adjustment time or the instrument was left wth a low battery for too long A pressure sensor error is shown in the pressure draft There is a calibration problem Send the instrument to screen a service center The analysis screen gives a flue gas temperature Tf a The thermocouple is not connected connect the error thermocouple to the analyzer b The se
24. 1 Checking and replacing the batteries The status of the internal battery can be checked during instrument auto calibration or even after if necessary by pressing the information key Hand accessing the battery capacity submenu The menu displays the battery s residual capaaty and voltage If battery charge appears to be low let it discharge completely and then carry out a full 100 charge cyde by connecting the instrument to the power pack for 3 hours If the problem persists replace the battery pack with a E Instruments orginal or contact the SERVICE CENTER to carry out the necessary repairs The average life of the battery pack is 500 charging discharging cydes To take advantage of this to the fullest capability it is advisable to always use the instrument powered by the internal batteries and to charge it only when it gives the battery flat message ATTENTION THE INSTRUMENT IS SHIPPED WITH THE BATTERY HALF CHARGED SO IT IS ADVISABLE TO CHARGE IT COMPLETELY BEFORE USE TAKING 3 HOURS ITIS ADVISABLE TO CHARGE THE BATTERY AT AN AMBIENT TEMPERATURE RANGING BETWEEN 50 F AND 85 F 10 C AND 30 C 3 3 2 Use with external power pack The instrument can work with the batteries fully discharged by connecting the external power pack provided Kindly note that while the battery is charging some heat is generated which increases the instrument s internal temperature This may lower the accuracy of some readings The air temperature must
25. 1ppm resolution and more accuracy CO mid range CO concentration in the Rue CO high range CO concentration in the Flue 20 000 ppm full range 1 ppm resolution NO NO concentration in the Fue 100 000 ppm NO low range NO concentration in the Aue wth 0 1 ppm resolution and more accuracy SO2 SO2 concentration in the Flue SO2 low range SO2 concentration in the Flue wth 0 1 ppm resolution and more accuracy NO2 NO2 concentration in the Flue NO2 low range NO2 concentration in the Flue with 0 1 ppm resolution and more accuracy CO2 CO2 concentration in the Flue Tf Flue Gas Temperature Ta Ambient Room Combustion air temperature Calculated values are Xair Excess of air ratio between the combustion air volume and the volume demanded by combustion under stoichiometric conditions COz Carbon dioxide percentage in the Fue gas CO diluted Increase system of the measurement range and protection of the CO sensor AT Difference between flue gases temperature and combustion supply air temperature NOx Nitrogen oxides concentration in flue gases Loss The sensible effidency value is to be compared against the minimum efficiency stated for the heating systems performances Eff Total efficiency It is the sum of sensible efficiency and the additional efficently deriving from the recovery of water vapour condensation contained in the flue gasses calculated according to the UNI 10389 1 standard When it is greater than
26. 530EEJ 01 917 5A0 19041 1 CO NO NO2 NOX Pressure Temperature MEASUREMENT UNITS CO NO NO2 NOX Pressure Temperature Pressure Temperature CO pp NO NO2 NOX ppm Pressure hpa Temperature O2 REFERENCE CO 8 02 NO NO2 NOX 0 co 0 0 NO NOz NOx 0 co NO NO2 NOX Pressure Temperature As SUES eS CO NO NO2 NOX Pressure Temperature NO NO2 NOX Pressure Temperature CO NO NO2 NOX Pressure Temperature O2 REFERENCE CO 19 0 NO NO2 NOX 0 lt gt CO NO NO2 NOX Measurement unit can be set as ppm mgm mg kWh g GJ g m gkWh Measurement unit can be set as ppm mg m mg kWh g GJ g m gkwh Measurement unit can be set as hPa Pa mbar mmH20 mmHg inH2O psi Measurement unit can be set as C w F O2 REFERENCE Po CO 1 y NO NO2 NOx 0 0 23 I CONTRAST CONF IGURAT ION Fuel A Pad Measurement units Oz Reference gt Display contrast Autozero Pump v Autozero Pump Fuel g pAutozero Measurement units Pump Oz Reference Display contrast pAutozero Pump Y AUTOZERO PUMP AUTOZERO PUMP Autozero Pump Autozero gt Pump CONF IGURAT ION gt CO AUTO DILUTION CO AUTO DILUT ION A Measurement units gt Mode off gt Mode oTt 02 Reference Display contrast Autozero Pump gt CO Auto Dilution Y v O AUTO DLLUT LON O AUTO DILUT LON Mode auto pLIMIt 4000 ppm w CONFIGU
27. 9 4 9 Configure Menu This menu is used to configure the instrument s reference parameters described below Fuel Lets the user select the type of fuel to be used during analysis This datum can be changed either from this menu or during the analysis itself Measurement units Through this submenu the user can modify the units of measurement for all the analysis parameters depending on how they are used O2 Reference In this mode the user can set the oxygen percentage level that pollutant emission values are corrected to for that given O2 reference level Display contrast The display contrast may be increased or decreased by acting on cursor keys OAV This operation may be perfomed even when the introductory screen is active Autozero Pump This submenu is used to set the duration of the analyzer auto calibration cyde It may also be used to switch off or switch on the sample pump temporarily The sample pump cannot be switched off if the auto calibration cyde is under way CO Auto Dilution The CO sensor is protected by a pump whioh in case of need can inject dean air in the gas path in order to dilute the gas concentration measured by the sensor This function can be either triggered by the overcoming of a CO ooncentration threshold which can be set by the user or in case it is known that the flue gases contain high CO concentration kept enabled any time independent of CO concentration WARNING CO Auto Dilution
28. ABORT P1 100 00hPa P2 99 99hpa 0 Qref 0 Result tigh ISTO1530EEJ 019175A0 190411 45 4 15 Flow Chart Configure Analysis Menu When depressed for at least 2 seconds turrs the instrument on E instruments A Et lt gt Adjusts the display contrast 4400 s w SN 00001_ ver 1 00 WARNING Insert the gas probe in the chimney Or automatically after 10 seconds Key analyzer parameters can be corfigured gt Mem during auto calibration The and keys Fuel Natural gas Date 19 10 10 38 8 respectively confirm and c ncel any efected Oper Time 1 Rep full Name John smith modifications and take the user back to the Mode manual previous level menu Autozero r25 Natural gas In the Select menus the cursor indicates the Bat 94 Z Diesel oil P at 94 Z N SE si activ ev alue Time 11 33 Date 09 18 03 Methane Autozero cycle end AUTOZERO STARTED WARNING OPERATOR ID In this phase one can either select the test var operator andor change the name displayed Now it is OK to Insert Probe in refer to Configure Menu Stack Setup the report printing selecting the number of copies and the type d report to print Or automatically after 10 sec At this point the user can select the analysis mode automalic or manual f automatic mode is chosen the test time and printout fomat must also be set manual EE sqa Gesa s The Configure Analysis Menu can also b
29. CAUSES AND REMEDIES The rear lighting of the display is not on The backlighting LED s are faulty Contact the nearest service center to replace the display The batteries last less than 9 hours a Battery capacity is limited by low temperatures To achieve a longer battery life itis recommended to store the instrument at higher temperatures b The battery pack is old Battery capacity tends to diminish with age F battery life has become unacceptable replace the battery pack The values shown in the analysis screen are not la Sensor s is are faulty Check that the sensors are installed correctly by accessing the sensor diagnostics menu b The sample probe connection has a leak Check all joints and the conditions of the hose c Pump is faulty Replace the pump unit d The instrument is faulty Send it to a service center for repair During the tightness test a sensor error isreported Check for the correct connection of the hose to the positive pressure input 68 IST01530EEJ 019175A0 190411 8 0 SPARE PARTS AND TECHNICAL 8 1 Spare parts AAC BF01 AAC FA01 AAC NI01 AAC PB02 AAC RCO1 AAC SE11 AAC SE12 AAC SE10 AAC SE14 AAC SE13 AAC SE17 AAC SE18 AAC SE24 AAC SE25 AAC SE26 AAC SE28 Sensor junction block Particulate filter Ink ribbon for printer Battery pack 5 x 6V 1800 mAh elements Paper roll for printer h 57 mm diam 40 mm FLEX Sensor O2 pre calibrated and interchangea
30. K temperature Y 0 01hPa 0 00hPa ZERO HOLD Ambient CO NO Pressure gt Tightness test TC K temperature Y k Ambient CO NO Pressure Tightness test gt TC K temperature Y 100 0 c A Ambient CO NO Pressure Tightness test TC K temperature gt Pt100 temperature 40 gt ma lt In the Smoke menu the user can input the smoke value The values entered with the arrow keys can be associated with the ongoing analysis through the key or printed with the Print menu The CO NO ambient gas gives a measurement about the safety of the environment in which the operator is working The concentration values can be associated to the ongoing analysis with the key or printed on a ticket through the Print menu PRESSURE PRESSURE 0 00hPa 0 00hPa ZERO See the TIGHTNESS TEST flow chart next page IST01530EEJ 01 917 5A0 19041 1 Tightness test flow chart according to standards UNI 7129 and UNI 11137 1 New piping pStart test Existing piping Stabilization Start test wait time 15 min gt pwait time gt Stabilization E min W wwait time Tin Start test WARNING Stabilization Charge the pipe to the test pressure 100 00 hPa Pressurize the piping and select TEST with the key During stabilization the pipe pressure P is displayed and also its variation AP during the last minute APT 00hPa The stabilization wait time is the one set in the test
31. POSITION S2 POSITION S4 The upgrading of the number of sensors can be easily done by the user by performing the following directions Both the expandable instruments are arranged in a way to accept one or two additional sensors in positions S3 and S4 Identify with the help of paragraph 5 2 Sensor types and relevant positoning the sensor s which must be added to the existing configuration To install the new sensors follow all the steps described in the paragraph MAINTENANCE under gas sensors replacement 56 IST01530EEJ 01917 5A0 190411 60 MAINTENANCE 6 1 Routine maintenance This instrument was designed and manufactured using top quality components Proper and systematic maintenance wil prevent the onset of malfunctions and will increase instrument life altogether The following basic requisites are to be respected e Do not expose the instrument to substantial thermal shocks before use If this happens wait for the temperature to return to normal working values e Do not extract flue gas samples directly without using a particulate water trap e Do not exceed sensor overload thresholds e When the analysis is over disconnect the sample probe and let 4400 draw fresh air for a few minutes or at least until the displayed parameters return to their original values e Clean the filter unit when necessary replacing the particulate filter and applying a jet of air to the sample probe hose to remove any condensate that ma
32. RATION AUTOMATIC ANALYSIS AUTOMATIC ANALYSIS A O2 Reference Display contrast Autozero Pump CO Auto Di lution pAutomatic analysis Y Mode ads Duration manual manual Print 120s manual 120 s Duration pPrint Duration Print 24 AUTOMATIC ANALYSIS Autozero Pump AUTOZERO PUMP Autozero Pump CO AUTO DILUTION Mode O AUTO DILUT LON Mode Duration Print manual Duration Print EIs manual Duration Print Note The pump cannot be switched of during auto calibration If auto calibration has not been perfomed the pump cannat be switched on CO AUTO DILUTION IST01530EEJ 01 917 5A0 19041 1 I I I I CONF IGURAT ION gt A Display contrast Autozero Pump CO Auto Di lution Automatic analysis gt Condensation Y CONF IGURAT ION gt A Autozero Pump CO Auto Di lution Automatic analysis Condensation gt Time Date Y CO Auto Dilution Automatic analysis Condensation Time Date yAlarms Y IST01530EEJ 01 917 5A0 190411 CONDENSATION gt Altitude R H air Altitude PR H air TIME DATE 12 12 12 12 12 EU w TIME DATE Time 12 12 gt Date 12 12 12 Mode EU w 12 12 12 12 12 EU ARM CONDENSATION Hd Altitude R H air Altitude R H air TIME DATE 12 12 12 12 EU TIME DATE 12 12 12 12 12 Number Measure Active Limit Unit ppm CO ev maximum 2000 A ARM Number
33. analysis Display average Select memory Recall memory Delete single Y Display average Select memory Recall memory Delete single gt Delete all 30 WARNING Delete all data in the memory 001 DUIT DELETE WARNING Delete all data in all memories DUTT DELETE WARNING Delete all data in the memory 001 QUIT DELETE WARNING Delete all data in all memories QUIT alana 1 19 12 10 15 30 2 19 12 10 16 00 3 19 12 10 16 30 Average analysis gt Meas Conditions Y Natural gas Altitude 0 m R H air 50 Mario Rossi 2 19 12 10 16 00 3 19 12 10 16 30 Average analysis 0 12hPa Meas Conditions external 20 C Y RECALL MEMORY RECALL SMOKE 3 19 12 10 16 30 WARNING Average analysis Requested data Meas Conditions are_not Draft avai lable gt Smoke Y RECALL MEMORY AMBIENT CO NO Average analysis Meas Conditions Orem Draft Smoke pAmbient CO NO WARNING Delete all data in the memory 001 Please wait WARNING Delete all data in all memories Please wait IST01530EEJ 01917 5A0 19041 1 4 11 Print Menu This menu is used to access the following piint and check configurations Print analysis report Shows the details of the selected ticket type and allows to start printing Configure Print Allows to set the number of printed copies and layout of the ticket The ticket layout selection is only valid for combustion analysis and can be chosen among Complete Part
34. ater than 10 Pa leak when the pressure drop is smaller than 10 Pa Positive pressure changes are symptom of a temperature change meanwhile the test is performed Should this happen it is advisable to repeat the entire test Existing piping The standard UNI 11137 1 can be adopted for testing already existing internal piping systems This test requires to charge the piping up to the test pressure then wait for an unspecified stabilization time until the thermal effects caused by the test gas compression are nulled and then calculate the amount of the possible leakage from the measure of the pressure decays in 1 minute time The test pressure should be as close as possible as the reference conditions following explained REFERENCE CONDITIONS According to the combustible gas to be used in the piping the tightness test must be perfomed in one of the following reference conditions City gas Reference pressure for test with supply gas 1000 Pa Test pressure with air 5000 Pa Natural gas Reference pressure for test with supply gas 2200 Pa Test pressure with air 5000 Pa L P G Reference pressure for test with supply gas Standard to be defined Somebody proposes 5000 Pa Test pressure with air Standard to be defined Somebody proposes 5000 Pa Note 4400 allows the user to perfom the tightness test even wth a combustible gas different from the supply gas Anyway the reference standard does not provide a reference pressure in this situation so the
35. atically after 10 seconds manual I Select analysis mode gt T outdoor 20 C WARNING Record the draft v alue Use P positive Inlet pRefO Auto 001 Mm Ambient CO NO Pressure Enter the Smoke values Tightness test TC K temperature Y IST01530EEJ 019175A0 190411 49 How to proceed in manual mode standard sequence pSave analysis Display average Select memory Recall memory Delete single Y pSave analysis Display average Select memory Recall memory Delete single Y pSave analysis Display average Select memory Recall memory Delete single v gt Save_analysis Display average Select memory Recall memory Delete single Y Print report Print setup Paper feed Print test report setup feed test report gt Memor Y setup Analysis 1 feed Mode full test PRINT QUIT Memory Draft smoke CO NO amb SAVE Memory Draft Smoke CO NO amb SAVE Memory Draft Smoke CO NO amb SAVE 7 Loss16 67 146p 40p 41p 51p SAVE test 1 SAVE test 2 SAVE test 3 Recall the average test values If desired set the preferred number of copies and analysis report format Print the analysis report When printing is complete return tothe Analysis Menu by pressing 50 The system is ready to carry out further tests IST01530EEJ 01917 5A0 19041 1 How to proceed in manual mode quick sequence Z Eff 83 47 Z Loss16 67 Memory praft Smoke
36. atus cal ok The 3 minutes stabilization time was not observed The sensor might be damaged or exhausted and needs to be replaced It is always possible to bring back the original calibration with the action set original and bring back the last on site calibration with set user 64 IST01530EEJ 019175A0 190411 6 8 Replacing the battery pack Follow these instructions to replace the battery pack Undo the fixing screw on the battery Remove the battery pack compartment cover and removeit Remove the battery pack connector and replace the pack with a new one following the reverse procedure described above Battery pack connector ISTO1530EEJ 019175A0 190411 65 6 9 Replacing the printer paper Follow these instructions to change the paper roll in the printer Remove the printer cover by exerting a light Push in the plastic thin plate to remove the pressure outward as shown by the arrow cover of the paper compartment as shown by the arrow until the cover comes out Fit the paper roll as shown in the figure 4 Fit the paper compartment cover again and insert the final part of the report into the slot of the printer indicated by the arrow Q Now let the report paper move forward through the print menu paper feed while accompanying the pining por hane Fit the printer cover taking care to insert the paper into the slot on the printer cover 66 IST01530EEJ 01917 5A0 190411 7
37. ble FLEX Sensor CO H2 pre calibrated and interchangeable FLEX Sensor NO NOx pre calibrated and interchangeable FLEX Sensor NO2 pre calibrated and interchangeable FLEX Sensor SO2 pre calibrated and interchangeable FLEX Sensor CO 10 00 pre calibrated and interchangeable FLEX Sensor CO 20 000ppm pre calibrated and interchangeable FLEX Sensor CO H2 low range pre calibrated and interchangeable FLEX Sensor NO low range pre calibrated and interchangeable FLEX Sensor NO2 low range pre calibrated and interchangeable FLEX Sensor SO2 low range pre calibrated and interchangeable 8 2 Accessories AAC AL04 AAC CRO1 AAC CT01 AAC DP02 AAC KP01 AAC KT 02 AAC PMOT AAC SA04 AAC SF21 AAC SF22 AAC SF25 AAC SF26 AAC SL02 AAC SM03 AAC SW03 AACTA03 AAC TAOST AAC UA02 100 240V 12 VDC 2A power supply with 2 m cable Rigid plastic case Shoulder bag Deprimometer for Draft test Differential pressure kit Tightness test kit Manual pump kit for smoke measurement filters Smoke chart Air temperature probe cable length 3 m 180 mm gas probe 1100 C extended temperature range wth 3 mt cable 300 mm gas probe 1100 C extended temperature range with 3 mt cable 750 mm gas probe 1100 C extended temperature range with 3 mt cable 1000 mm gas probe 1100 C extended temperature range with 3 mt cable 220 mm flexible gas probe 1100 C extended temperature range with 3 mt cable Rubber protecting cover wih magnets
38. cur oie N ssion g s S 3 y orga 4 Y diy AO SN oQ E INSTRUMENTS 4400 Portable Combustion Gas Analyzers TABLE OF CONTENTS 1 0 INTRODUCTION 1 1 General Description ofthe Combustion Analyzer 1 2 General features of the Flue Gas Analyzer 13 4400 Main configurations 2 0 TECHNICAL SPECIFICATIONS 2 1 Technical Specifications 2 2 Overview of Flue Gas Analyzer Components 23 Measurement and Accuracy Ranges 3 0 USING THE FLUE GAS ANALYZER 3 1 Preliminary operations 32 Warnings 33 Analyzer power supply 3 3 1 Checking and replacing the batteries 3 3 2 Use with external power pack 4 0 OPERATION 4 1 Working principle 42 Measurement cells 43 Connecting the Sample probe 44 Condensate trap and fine dust filter 4 5 Connecting the combustion air temperature probe 4 6 Connecting the TcK probe 4 7 Keypad overview 4 8 Info Menu 4 8 1 Flow Chart Info Menu 4 9 Configure Menu 4 9 1 Flow Chart Configure Menu 4 10 Memory Menu 4 10 1 Flow Chart Memory Menu 4 11 Print Menu 4 11 1 Flow Chart Print Menu 4 12 Analysis Menu 4 12 1 Zoom Menu 4 12 2 Flow Chart Analysis Menu Zoom 4 13 Draft Menu 4 13 1 Flow Chart Draft Menu 4 14 Readings Menu 4 14 1 Flow Chart Readings Menu 4 15 Flow Chart Configure Analysis Menu 4 16 Flue Gas Analysis 4 16 1 Switching on the instrument and auto calibration 4 16 2 Inserting the probe inside the stack 4 16 3 Flue Gas Analysis 4 16 4 End of Analysis 4 16 5 Flow Char
39. ded for the maintenance of the pipe in order to fix the leakage problem and in any case for no more than 30 days after the testing day Once the fixing has been completed the piping must tested again forits tightness according to the UNI 7129 standard Non compliant not suitable for operation when the leakage flow is greater than 5 dm h In this situation the measured leakage is such that the piping is not suitable for operation and must immediately placed out of order Once the leakage problem has been fixed the piping must tested again forits tightness according to the UNI 7129 standard TcK Temperature The user can measure the temperatures within the range spedfied in the technical specifications e g plant delivery temperature by using an OPTIONAL Type K thermocouple contact probe connected to the TcK input Pt100 Temperature The ambient temperature can be measured within the range specified in the technical specifications by connecting the remote airtemperature probe provided with the instrument to the Pt100 input IST01530EEJ 019175A0 190411 39 4 14 1 Flow Chart Readings Menu Acti ates the Smoke Menu pMeasure Measure Measure report setup feed test Ambient CO NO Pressure Tightness test TC K temperature Average v k report pAmbient CO NO setup Pressure fee Tightness test test TC K temperature Y MEASUREMENTS PRESSURE PRESSURE Smoke Ambient CO NO Pressure Tightness test TC
40. dirty see chapter MAINTENANCE ATTENTION KEEP THE CONDENSATE TRAP IN THE VERTICAL POSITION DURING THE ANALYSIS A WRONG POSITIONING MAY CAUSE CONDENSATE TO LEAK INTO IN THE INSTRUMENT AND DAMAGE SENSORS AFTER EACH ANALYSIS CHECK FOR ANY PRESENCE OF WATER IN THE CONDENSATE COLLECTION BOWL AND REMOVE IT IF ANY PUT THE PROBE BACK IN THE CASE ONLY AFTER YOU HAVE REMOVED CONDENSATE FROM THE TUBE AND THE EXPANSION TANK SEE CHAPTER MAINTENAN CE REPLACE THE FINE DUST FILTER IF ITIS VISIBLY DIRTY OR WET SEE CHAPTER MAINTENANCE DO NOT PERFORM ANY MEASUREMENT WHEN THE FILTER IS REMOVED OR DIRTY IN ORDER TO AVOID ANY RISK OF PERMANENT DAMAGES ON SENSORS 4 5 Connecting the combustion air temperature probe Should you need to measure the actual combustion air temperature and the analyzeris notin the place where the combustion air is to be taken important for a correct calculation of the bumer effidency you shall use the remote probe The remote probe is made up of a Pt100 thermal resistance equipped with cable 3 meterslong and connector for its connection to the analyzer 4 6 Connecting the TcK probe Using the same input as for the K thermocouple the same used for flue temperature itis possible to measure the water delivery and return temperature by connecting some special probes If temperature is taken on the pipe itis suggested to use arc probes with a suitable diameter 16 IST01530EEJ 019175A0 190411 4
41. e Oper j j j Rens ful1 accessed after auto calibration is complete Mode manual pRefO Auto 001 Biv 46 IST01530EEJ 019175A0 190411 4 16 FLUE GAS ANALYSIS To perform complete flue gas analysis follow the instructions below ATTENTION SOME IMPORTANT WARNINGS TO CONSIDER DURING THE COMBUSTION ANALYSIS ARE LISTED BELOW FOR A CORRECT ANALYSIS NO AIR MUST FLOW INTO THE PIPE FROM OUTSIDE DUE TO A BAD TIGHTENING OF THE CONE OR A LEAK IN THE PIPELINE THE SAMPLING PROBE amp HOSES MUST BE CHECKED IN ORDER TO AVOID ANY LEAKAGES OR OBSTRUCTIONS ALONG THE PATH THE CONNECTORS OF THE SAMPLE PROBE AND THE CONDENSATE FILTER WATER TRAP MUST BE WELL CONNECTED TO THE INSTRUMENT KEEP THE CONDENSATE TRAP IN THE VERTICAL POSITION DURING THE ANALYSIS A WRONG POSITIONING MAY CAUSE CONDENSATE LEAKAGES IN THE INSTRUMENT AND THUS DAMAGE THE SENSORS DO NOT PERFORM ANY MEASUREMENT WHEN THE FILTER IS REMOVED OR DIRTY IN ORDER TO AVOID ANY RISK OF PERMANENT SENSOR DAMAGE 4 16 1 Switching on the instrument and auto calibration Press the On Off key to switch on the instrument an introductory screen will appear Aftera couple of moments the instrument will zero itself and will state that the sample probe should not be inserted in the stack In case the instrument is equipped with the electrovalve for automatic auto zeroing it will ask for the insertion of the gas probe in the stack On the other hand if the instrument has not the elec
42. e 482 x 37 5 x 16 cm Wx H x D Weight Analyzer 1 1 kg Compliant wth the CEI EN 503792 European Standard IST01530EEJ 01 917 5A0 19041 1 7 2 2 Overview of Flue Gas Analyzer Components LEGEND Q Keypad Display Cover to access the impact printer D Flue Sampling probe Condensate separator and fine dust filter unit Water Trap Assembly Compensated male connector of the fumes exhaust temperature probe Combustion air temperature probe H P connector negative input for measuring differential pressure Q A connector sample probe input by means of the water trap P connector positive input for measuring draft Temperature Tc K female connector Battery charger socket 0 Serial cable socket for connecting to the draft gauge and to the ancillary probes P Mini USB socket for connecting to a PC Q Female connector for conneding the combustion air probe Incoming Air Condensing Units 8 IST01530EEJ 01 917 5A0 19041 1 Keypad Adhesive polyester keypad with prefomed keys featuring main control functions pos in Fig 2 2 Displa Back t128 x 64 pixel LCD display pos Q Fig 2 2 with 8 lines x 20 characters available Allows the user to view the measured parameters in the most comfortable format a Zoom function displays the measured values in magnified form CAUTION If the instrument is exposed to extremely high or extremely low temperatures the quality of the display may be temporarily impai
43. e perfoms a full check on the physical effidency of all types of HW memories installed on the instrument as well as on the integrity of the data stored into them Any issue is evidenced in the screen Memories Diagnostics Should this happen it is advisable to turn the instrument off and then on again In case the problem is permanent or frequently recurring the user should contact the Service Center reporting the error code shown by the instrument Info service This submenu contains details regarding the nearest Service Center to be contacted in the event of instrument fault or ordinary maintenance The instrument model serial number and firmware version are also displayed thus allowing for a quick product identification The Flow Chart in the following page shows how to browse through the Info Menu screens 18 IST01530EEJ 019175A0 190411 4 8 1Flow Chart Info Menu Activ ates the Info Menu pBattery status Bat 91 7 Sensors Config vbat 7 82 V Sensors diagnostic Memories diagnostic Info Service Battery status gt Sensors Config Sensors diagnostic Memories diagnostic Info Service Battery status Sensors config Memories diagnostic Info Service Memories Battery status Calibration Sensors config Sensors diagnostic Memories diagnostic Info Service Battery status E Instruments Sensors Config Tel 3433 720 124 Sensors diagnostic 215 750 1399 M
44. easurement cells used in the analyzer are O2 20 sec at 90 of the measured value CO H2 50 sec at 90 of the measured value CO 50 sec at 90 of the measured value NO 40 sec at 90 of the measured value NO2 50 sec at 90 of the measured value SO2 50 sec at 90 of the measured value It is therefore suggested to wait 5 minutes anyway not less than 3 minutes in order to get reliable analysis data If sensors of poison gases are submitted to concentrations higher than 50 of their measurement range for more than 10 minutes continuously they can show up to 2 drift as well as a longer time to return to zew In this case before turning off the analyzer it is advisable to wait for the measured value be lower than 20ppm by intaking dean air The CO sensor can be protected from high gas concentrations through the dilution function which allows for a wider measurement range of the sensor without overcharging the sensor itself 4 33 Connecting the sample probe The sampling probe is made up of an INOX steel tube with a plastic hand grip and an internal K type thermocouple Ni NiCr for measuring the fumes temperature up to 800 C The probe is connected to the analyzer through a double flexible hose a filter group and a compensated cable for the thermocouple The polarized connector of the thermocouple is to be connected to the special outlet on the lower side of the instrument Itis not possible to perform a wrong connection thanks to t
45. efore the stabilization phase ends Once the stabilization phase is terminated the tightness test is started This test is performed by observing how the pressure decays in time during a fixed 1 minute interval as stated in the applied standard During the tightness test phase the following values are displayed P1 Pressure measured at the beginning of the test P2 Pressure actually measured by the instrument AP Pressure variation with respect to the initial value In case the actual pressure is lower than the initial value pressure is decreasing this value has a negative sign Qtest Is the calculated leakage measured in dm h according to the conditions under which the test has been perfomed i e the gas used forthe test as well as the final pressure measured during the test Qref is the calculated leakage measured in dm h according to the reference conditions described in the standard itis related to the gas to be used in the piping as well as to the reference pressure Result isthe result of the tightness test Compliant piping suitable for operation when the leakage flow calculated in the reference conditions is lower than 1 dm h The system is authorized to operate wihtout restrictions or intervention Compl 30 DD piping temporarily suitable for operation when the leakage flow calculated in the reference conditions is induded in the range 1 dm h lt Qrif lt 5 dm h The system is authorized to operate only for the time nee
46. elated to the consumption of the reagents within Sensor characteristics diminish as the reagents are consumed and when these have been used up completely the sensor must be replaced The sensors must be recalibrated on a regular basis to assure measuring accuracy recalibration can only be performed by a qualified E Instruments service center Chart 5 4 illustrates the characteristics inherent to each sensor 5 4 Gas sensors life ak notnecessary FLEX Sensor CO CO 100 000 Purple 48 months Yeay FLEX Sensor CO 20 000 Blue 48 months Yeally arbon M onox de FLEX Sensor CO H2 CO e s Carbon M onox de FLEX Sensor NO2 NO2 Cod AG526 W00 White 36 months Yeay FLEX Sensor SO SO2 48 months Yeally 2 FLEX Sensor NO NO low range iW a 48 months Yeay 2 Cod AACSE25 itrogen Oxide FLEX Sensor NO2 NO2 low range 2 FLEX Sensor SO SO2 low range BEE 48 months Yeaty 2 Cod AACSE28 ei ok Notes 1 Coloured dot on the sensor electronic board 2 UNI 10389 1 standard requires for the instument calibration once per year to be performed in a laboratory authorized to issue calibration certificates IST01530EEJ 019175A0 190411 55 5 5 Expandability to 4 sensors In the 4400 instrument range two are the versions which can be expanded 4400 2 sensors expandable to 3 or 4 sensors 4400 1 3 sensors expandable to 4 sensors POSITION S1 ePOSTTION SS k a 5 POSITION S2 POSITION S4
47. emories diagnostic 4400 s Info Service SN 000001 Ver 1 00 PN 000000 IST01530EEJ 01 917 5A0 19041 1 To return to the previous screen press a The battery symbol filling up means that battery charging is ongoing This screen page shows for each position the following messages example referredto thesensor in position 2 CO Sensor corfigured OK CO Sensor missing or non communicating CO nu New sensor detected CO Sensor detected in a wrong position Use arrows AN to scroll the parameters of each selected cell Here below are the data which can be displayed through the sensors troubleshooting menu Type Ty pe of sensor Revision Sensor revision index Date code Production batch Gas Gas measured Serial Sensor serial number Manufacturing date Production date Calibration date Calibration date Is Sensor Is current la Sensor la current Furthermore under sensor troubleshooting mode the instrument can display the status of each single cell here is an example visualized after the visualization of the measured gas Ok No problem detected missing The sensor has not been detected data err Sensor memory data error Unknown The instrument FW needs to be updated pos err Sensor installed in the wrong position cal err Calibration error curr err Currents out of range non config This sensor is not to be used because it has not been accepted in the page ty pe of sensor 1
48. ental loss of the formerly stored data Delete all This is used to cancel the entire contents of the 300 memory positions even for this option a confirmation is required in order to avoid an accidental loss of the formerly stored data 28 IST01530EEJ 019175A0 190411 4 10 1 Flow Chart Memory Menu Activates the Memory Menu This menu is used to display and print the individual and av erage v alues of the analysis data stored in memory Analysis data can be ordered either by memory position or by storage date draft smoke and ambient CO NO values can also be recalled Inside the Recall Memory menu the Print Menu is only enabled in the analysis screen or in the draft smoke and ambient CO NO values screen rSave analysis Display average Select memory Recall memory Delete single Y Save analysis Display average gt Select memory Recall memory Delete single Y MEMORY gt pSave analysis Display average Select memory Recall memory Delete single Y Save analysis Display average Select memory Recall memory Delete single Y Save analysis Display average Select memory gt Recall memory Delete single Y IST01530EEJ 01 917 5A0 190411 Standard UNI 10389 1 stipulates that the combustion efficiency has to be calculated on the basis d the average values of three readings Three tests must therefore be memorized There are 300 storage areas each of which is capable of storing three
49. f the optional PC configuration program this list and the relative coefficients may be modified for up to a total of 10 fuels The following chart derived from standard UNI 10389 1 lists the coefficients of the seven memorized fuels used for calculating losses and efficiencies Coefficients for calculating combustion efficiency 8 con Fe a Smoke measurements It is possible to enter the smoke values measured according to the standard Smoke index scale The instrument will calculate the average and print the results in the analysis report An external smoke pump available as an optional must be used to correctly take this measurement Pressure decay test The instrument can perfom the tightness test of a piping according to the Italian standards UNI 7129 and UNI 11137 1 For this test the same pressure sensor used is the same as that for the draft test 10 IST01530EEJ 01917 5A0 190411 Measuring ambient CO Probe for monitoring the concentration of CO and checking safe conditions in the boiler room An acoustic and visual warning signal is given if the thresholds are exceeded according to the OSHA levels Internal gas leak detector sensor This sensor searches for explosive gas leaks in the pipes External low pressure sensor draft gauge This sensor is a particular draft gauge with precision 0 5 Pa and resolution 0 1 Pa characteristics higher than those of the sensor installed inside the instrument This
50. feature must only be considered as a means of protection for CO sensor as its activation heavily deteriorates both accuracy and resolution of the CO measurement Automatic analysis The user can set analysis mode to either manual or automatic In manual mode the user perfoms the three necessary analysis operations manually In automatic mode the cycle duration for each reading must also be set in this case the instrument will conduct each analysis in the specified time Printing may also be manual orautomatic If auto printing is selected the instrument will automatically print the analysis reportin a predetermined format at the end of the automatic analysis If auto printing is selected also at the end of a tightness te st a report will be printed automatically Condensation The burner efficiency figure when condensation takes place is influenced by atmospheric pressure and humidity of the combustion air As the atmospheric pressure is hardly predsely known the operator is asked to enter a related parameter i e the altitude of the place above the sea level from which the pressure is then derived once the dependency from atmospheric conditions is neglected In calculations the value of 101325 Pa is assumed as atmospheric pressure at sea level Further the air relative humidity input is allowed being this calculated at the combustion air temperature as measured from the instrument in case this value is unknow the operatoris recomme
51. he different width of contacts Connect the shorter tube of the probe to the filter group fine dust condensate trap which in turn shall be connected to the central connector of the instrument marked with letter A Connect the longer tube ending with a male connector to the negative pressure input of the instrument marked with letter P The different diameter of connectors does not permit any wrong connections this permits to avoid any damages to the instrument 4 4 Condensate trap and fine dust filter The sample gas to be analyzed shall reach the measurement cells after being propery dehumidified and purified from the residual combustion products To this purpose a condensate trap is used which consists of a transparent polycarbonate cylinder placed along the rubber hose of the sampling probe Its purpose is to decrease the air soeed so that the heavier fine dust partides can precipitate and the vaporin the combustion gases can condensate The condensate trap must be always kept in the vertical position in order to prevent condensate from touching IST01530EEJ 019175A0 190411 15 the measurement cells This is also the reason why it is important to periodically drain the trap anyhow at the end of each test see chapter MAINTENANCE A replaceable low porosity line filter is placed after the condensate trap aimed at keeping the solid partides suspended in the gases It is recommended to replace the filter whenever visibly
52. he filters are clogged or damp e Before putting the measuring probe back in its case after use make sure it is has cooled down enough and there is no condensate in the tube It might be necessary to periodically disconnect the filter and the condensate separator and blow compressed air inside the tube to remove all residues e Remember to have the instrument checked and calibrated once a yearin order to comply with the existing standards ATTENTION IF THE INSTRUMENT HAS BEEN KEPT AT VERY LOW TEMPERATURES BELOW OPERATING TEMPERATURES WE SUGGEST WAITING A WHILE 1 HOUR BEFORE SWITCHING IT ON TO HELP THE SYSTEM S THERMAL BALANCE AND TO PREVENT CONDENSATE FORMING IN THE PNEUMATIC CIRCUIT 3 3 Analyzer power supply The instrument contains a high capacity Lilon rechargeable battery The battery feeds the instrument built in printer and any other probes or remote devices that may be connected The instrument runs for approximately 18 hours if the printeris not used Should the battery be too low to effect the necessary measurements the instrument can be hooked up to the mains via the power pack provided allowing operations and analysis to proceed The battery will be recharged whilst the instrument is being used The battery charging cycle takes up to 3 hours for a complete charge and finishes automatically ATTENTION If the instrument is not going to be used for a long time we suggest recharging it at least once every 2 months 3 3
53. he settling time is reduced down to 2 hours IST01530EEJ 019175A0 190411 61 6 7 On site recalibration lt is possible to make a recalibration of the instrument s gas sensors with known concentration gas cylinders Recalibration of Oxygen O2 sensor is not available since it is already recalibrated during every autozero cycle The access to the sensor recalibration is password protected the password is 1111 To carry on the recalibration the following instruments are needed Known concentration gas cylinder suitable for the sensor complete with a pressure regulator Flow meter Hose with Tee fitting to connect the cylinder to the flowmeter and to the instrument 6 7 1 Flow Chart On site recalibration Og When depressed for at least 2 seconds turns the instrument on SN 00001 ver 1 00 WARNING Insert the gas probe in the chimney ATTENTION Do not connect the gas probe to the instrument S E instruments ATTENTION Make sure autozero is executedin clean air 4400 s Or automatically after 10 seconds ATTENTION MULDER roses Check the battery charge level or connect the Bat 94 7 Time 11 33 Date 09 18 03 Autozero cycle end power adapter to avoid data loss during recalibration AUTOZERO COMPLETED WARNING Starting combustion analysis Or automatically after 10 seconds O2 4 27 coz 9 3 pRefO2 Auto 001 WW 62 IST01530EEJ 019175A0 190411 Depress 7 key and with AS
54. hich allows to freeze the value shown on the display by pressing HOLD key Tightness test 4400 can perfom the tightness test on heating plants which use combustible gases according to the standards UNI 7129 and UNI 11137 1 respectively applicable to new or renewed pipings and to existing pipings The result of this tightness test whose steps are described in the following can be printed once acquired by starting the print menu in any of the screens of the Tightness Test menu New piping The standard UNI 7129 can be adopted for testing new piping systems or reconditioned ones This test requires to charge the piping up to a pressure of atleast 100 hPa then wait for a stabilization time of at least 15 minutes required for nulling the thermal effects caused by the test gas compression and finally check for the tightness of the piping by analysing the way the pressure eventually decays against time This check expects for no difference between two pressure readings performed in 15 minutes and wth a manometer having a minimum resolution of 10 Pa 4400 allows the user to customize the stabilization phase through the following parameter WAIT TIME it isthe stabilization time and can be set by the user from 15 to 99 minutes Please note that UNI 7129 standard requires a stabilization time of at least 15 minutes anyway there is the possibility to skip stabilization by pressing button Once the stabilization parameter has been set
55. ial and Total Tickets for draft smoke ambient gas concentration and tightness test only allow a specific layout Layouts for combustion analysis are specified as described in the following Full indudesa header with company data as well operator data previously programmed in the configuration menu measurements sampled in the combustion analysis and when sampled the draft smoke and CO NO ambient gas values Partial only reports the combustion analysis measurement values and information without any header comments or blank lines for operator comments Total is arranged with the complete layout of the average analysis followed by the single analysis measurements report Advance paper Feeds paperin the printer this function is most useful when replacing the paper roll in the printer Trial print Prints a graphical alphanumeiic test ticket for a complete check of the printer operation ISTO1530EEJ 019175A0 190411 31 4 11 1 Flow Chart Print Menu amp Enables the Print Menu Allows to print the combustion analysis data on a paper ticket which reports the measuremert values The printed values are those shown on the display when the menu is enabled This menu can be usedfor combustion analysis ev en when recalled from the memory for draft smoke ambient gas andfor tightness test results report setup feed test EE s gig HO peis aal w ezis Print test Sev eral copies of the test ticket can be printed
56. in the flue gas are typically not far from very low values 3 hence itis possible to obtain the NOx value by a simple calculation without using a direct measurement with a further NO2 sensor The NO2 percentage value contained in the fumes can be however set at a value other than 3 default value Operator The name of the operator conducting the analysis may be set or modified through this submenu Amaxmum of three names may be stored The name of the selected operator wil be printed on the analysis report Report header setup This allows the Company or Owners name to be entered in four lines with 24 characters each together with other details e g address tel no This data will be printed on the heading of the analysis report Micromanometer Allows to configure the micromanometer input optional as P or P port In case P is selected the sign of pressure is inverted Language This sub menu permits to select the desired language for the visualization of the various menus and the report printing Calibration It is possible to make a recalibration of the instrument s gas sensors with suitable known concentration gas cylinders Recalibration of Oxygen 02 sensor is not availbale since it is already recalibrated during every autozero sequence See MAINTENANCE section ISTO1530EEJ 019175A0 190411 21 4 9 1 Flow Chart Configure Menu All selected data can be modified Activ ates the Configure Menu by pressing
57. int report analysis ruming the ticket with the draft value enable the PRINT print setup Mode draft menu through the relev ant key then proceed as in Paper fee Print test the combustion analysis printing A draft value aurr acquired into memory can be deleted by pressing again the draft key a series of dashes will appear in place of the measurement value after this select the KEEP option with e Once the data is stored the instrument progresses automatically from the Draft Menu to the Analysis Menu gt RefO2 Auto 001 ky NOTE The draft values to be stored in the memory must be acquired bef ore storing the analysis data 36 IST01530EEJ 01917 5A0 190411 414 Measurements Menu This menu is used to access the following readings Smoke lt is possible to enter the data for up to three 3 separate Smoke test measurements taken by means of an optional device SMOKE PUMP see the relevant instructions The method consists in taking a certain quantity of combustion gas from the middle of the flue behind the surfaces of the exchangers at the end of the boiler and make it pass through a special filter paper The soot stain obtained is compared with the surfaces blackened in a different way according to a comparison scale itis thus determined the soot number which will be entered in the instrument by hand These measurements can be either stored in memory together with the combustion analysis data or printed on
58. is used to measure the pollutants NO and NOx The most complete version can house a fourth sensor for measuring NO2 or SO2 CO NO NO2 and SO2 measuring sensors are also available with a reduced measuring range with a resolution of 0 1 ppm and better accuracy Two ena sensors measure the environmental parameters itis also possible to measure flue draft and carbon black and wth the measuring range of up to 200hPa system pressure and pressure in the combustion chamber can be measured and the pressure switches checked 4400 is designed for seven main types of combustible substances among which natural gas LPG Diesel fuel and fuel oil Another 16 types of which the chemical composition is known can be entered in its memory 4400 functions include storing and averaging the measurements acquired printing the results on ordinary rolls of paper and connecting to the computer for filing the data using a USB connection The memory can store 300 complete analyses and the data downloaded onto a PC by means of dedicated SW and a mini USB serial communication cable It is also interesting to note that 4400 has just one Li lon rechargeable battery pack used for powering the instrument and the printer it also has a luminous and large 42 x 60mm LCD display boasting excellent readability thanks to its backlighting and also to the zoom function Another characteristic that distinguishes it from other similar products in the mar
59. ket is the fact the power supply that comes with the product can carry out the dual function of battery charger and power supply for the instrument which means the user can carry out analyses even if the batteries are completely flat Another important function is the possibility of carrying out an autozero cycle with the probe inside the stack exploiting a sophisticated flow deviation system As far as concerns maintenance it is useful to know that the user can replace the sensors himself without having to send the instrument back to the technical Service center in fact the sensors are pre calibrated and 4400 does not need recalibrating Moreover e Operator interface user friendly so much so that it can be used without the instruction manual e Luminous and large LCD display easy readability thanks to the Zoom function and effective bacKighting e Built in impact printer using ordinary paper maximum readability and duration in time and to heat One battery pack rechargeable for powering the instrument and the printer indicating the charge level and is accessible from outside Pneumatic input connectors gas and pressure draft staying inside the profile of the instrument for greater resistance to knocks e Pre Calibrated sensors directly replaceable by the user 1 2 General features of the Flue Gas Analyzer 4400 is a portable flue gas analyzer that was meticulously designed to meet statutory requirements and specific
60. lect the nominal diameter with the keysw A Select the figure to be modified with the keys lt gt Modify the value of the highighted figure with keyswy AN Select material with keys vA Steel Copper PE Select the nominal diameter with the kysy A Select the figure to be modified with the keys p Modify the value of the highlighted figure with keyswA STAB ILI ZAT ION WARNING Zero piping volume QUIT 43 City gas mNatural gas L P G City gas Natural gas gt L P G Start test gt gt City gas Stabilization Natural gas Piping volume L P G Combustible gas Test gas city gas mNatural gas L P G Air EXISTING PIPING city gas Natural gas gt L P G Air City gas Natural gas PL P G PPD 44 IST01530EEJ 01917 5A0 190411 EXISTING PIPING EXTSTING PIPING gt EXISTING PIPING wstart test m WARNING tabilization arge the pipe to Piping volume the test pressure 0 06nea O OOnea Combustible gas 100 00 hPa Test gas EXISTING PIPING Pressurize the piping and select TEST with the key 100 OOnra During stabilization the pressure P in the piping is 100 00hpa shown together with the variation AP1 in the las 0 00hPa minute The waiting time is set in the tes Wait time 20 00 configuration menu The Stabilization can bg OK to proceed interrupted any time by pressing the key APT QUIT ABORT QUIT
61. move the cursor to Calibration A Operator e A Report header setup Enter the recalibration menu password Micromanometer Language 1111 gt calibration The installed sensors are shown and can be chosen for Action calibrate i i y applied recalibration e Measur In the calibration screenshot information about the Ta 0 17 uA calibration in use and sensor output are displayed Status original Action selection of action to make calibrate save new calibration set original bring back original factory AE z calibration Measured O OA set user bring back last completed user Status original calibration Applied selection of cylinder gas concentration ppm Measured Actual sensor reading Is Is current from the sensor EE la la current from the sensor 100 0 P Status Shows calibration status EE original factory original calibration in use Status original user user calibration in use saving calibration saving in progress user cal OK user calibration successful cal error user calibration error orig calok restore of original cal successful CHOOSE THE SENSOR TO BE RECALIBRATED AND PROCEED AS DESCRIBED CO SENSOR IS SHOWN IN THIS EXAMPLE e Connect the known concentration gas cylinder to the instrument as shown in the following scheme ZN ATTENTON Adequate ventilation must be provided when working with toxic gases particularly the flow meter and instrument outputs must be evacuated by aventilatio
62. mponents and reassemble the filter IST01530EEJ 019175A0 190411 57 6 5 Replacing the particulate filter If the particulate filter appears black espedally on the inner surface see adjacent example it has to be replaced immediately In this way gas flow is not obstructed Blackened partculate filte 6 6 Replacing the gas sensors The gas sensors of the instrument shall be periodically replaced see the following table with new or recalibrated sensors The user can easily perform this replacement operation according to the following instructions 9 Undo the two fixing screws on e Extract the cover to have access to the sensor compartment the sensor compartment cover 58 IST01530EEJ 01917 5A0 190411 Locate the sensor to be replaced here is an example of a connected sensor to be replaced ISTO1530EEJ 019175A0 190411 59 The sensor is bayonet connected to its socket rotate it counter clockwise to remove it Here is an example of a rotated sensor ATTENTION While rotating the sensor take care not to exert any pressure onto the printed circuit above apply pressure only onto the plastic body After rotating the sensor pull it upward here is an example of the sensor compartment with a sensor re moved Fit the sensor again taking care the electric connection is turned outside the instrument not inside See point 5 60 IST01530EEJ 01 917 5A0 19041 1 Rotate the sensor clockwise
63. n system GAS CYLINDER FLOW METER COMBUSTION ANALYZER a OP od OP IST01530EEJ 019175A0 190411 63 e Apply the gas to the instrument and regulate the cylinder output pressure so that the flow meter shows a minimum flow 0 5 I m to ensure that the instrumentis getting exactly the gas needed by its internal pump e The instrument measures the concentration of the applied gas wait at least 3 minutes for the measure to stabilize T he reading is shown in the Measured row CO CALIBRATION Action calibrate Applied 1000 0 P Measured ee P Is 22 UA Ia 10 17 uA Status original e Toi initiate the recalibration select the concentration of the applied gas cylinder concentration in the Applied row CO CALIBRATION Action calibrate ds ay D i With Awy keys set the cylinder concentration in the Applied 82 22 uA RN 10 17 uA Status original e Select Calibrate in Action row CO CALIBRATION Action calibrate Applied 1022 0 P Measured 990 5 P IS 82 22 uA Ia 10 17 uA Status original e Depress the e key to save the new calibration CO CALIBRATION The recalibration result will be shown in the Status row I CAL OK sensor recalibrated successfully pAction calibrate CAL ERROR sensor not recalibrated due to es ES P The gas was not correctly delivered to the Measure 5 P instrument 82 22 uA The applied gas concentration was not correctly 10 17 uA set in the Applied row St
64. nded to enter 50 for this value Time Date This allows the current time and date to be set The user can select the date and hour format either in EU European or USA Ametican mode Alarms This submenu allows the user to set and memorse 5 alams defining the monitored parameter for each the alarm threshold and relative unit of measurement and whether it is a low or high level alarm 20 IST01530EEJ 019175A0 190411 Low level alarms are triggered when the reading drops below the defined threshold whereas highdevel alarms are triggered when the reading rises above the defined threshold When an alam threshold is crossed the instrument emits an intemittent audible alarm besides activating a visible alarm wherein the background of the name of the relative reading will start flashing in the analysis screen When the CO and NO concentration thresholds are crossed besides activating the audible and visible alarms the CO and NO solenoid valves may also be set to intervene and thereby interrupt sample flow If the instrument is not fitted with a solenoid valve the sample pump will in any case be stopped Buzzer This sub menu allows the operator to activate or deactivate the instrument buzzer NOx NO Factor NOx NO all the nitrogen oxides which are present in the flue emissions Nitrogen oxide NO Nitrogen dioxide NO2 total nitrogen oxides NOx NO NO2 In the combustion processes it is found out that the NO2 percentage contained
65. nsor has been exposed to temperatures greater or lower than its operating temperature range c The themocouple is faulty Send the complete probe to a service center The following symbol appears on the analysis The instrument is not able to calculate a numerical screen value based on the flue gas analysis conducted The are replaced by numbers when the analyzer detects valid combustion data Max Lim or Min Lim appears on the analysis The relative sensor is detecting a value thatis beyond screen the analyzers measuring range Max Lim or Min Lim are replaced by numbers when the instrument reveals values that are within the measuring range The sample pump sounds as though it is runningla Sample flow is obstructed Check that the water filter slowly tends to stop or does not even start is clean and that it is not completely soaked Also check that the hose connected to the probe is not crushed b Sample intake flow is obstructed Check that the particulate filter is clean c The pump is not connected correctly Remove the rear flap and check that the pump s electrical connector is connected to the printed circuit board d Pump is faulty Replace the pump unit e Pump is disabled The key combination BA has been pressed To re enable the pump switch off the instrument and then switch it on again ISTO01530EEJ 019175A0 190411 67 Troubleshooting guide SYMPTOM PROBABLE
66. r is simplified by symbol keys that give direct access to main instrument functions Shifting between the various menu screens is easy and user friendly thanks to four cursor keys an key and Ba key IST01530EEJ 01 917 5A0 19041 1 5 1 3 4400 Main configurations N 4400 S Cod K9401A0004 Cod K9401A0005 300mm 12 10 Dual Hose ku 6 IST01530EEJ 01 917 5A0 19041 1 2 0 TECHNICAL SPECIFICATIONS 2 1 Technical Specifications Autozero Automatic autozero cyde with probe inserted in the stack Dilution Expansion system of the CO sensor measuring range up to 50 000ppm 5 00 v v programmable asa simple protection of the CO sensor with triggering threshold programmable by the user Preset tiggering threshold at 1 500 ppm Self diagnosis All the functions and internal functions are checked and anomalies signalled Type of Fuels Oils 7 predefined by the factory and 16 that can be programmed by the user Power Li lon battery pack with internal protection drcuit Battery charger External battery charger Charging time 2 hours for charging from 0 to 90 3 hours for 100 charge Instrument working time 16 hours of non stop operation exduding printing Printer Internal 24 column impact printer using ordinary paper roll 18 m long and 57 mm wide Printer powered By the analyzer batteries Printer autonomy Up to 40 analysis reports with the batteries fully charged Internal data memory 300 complete
67. red Display appearance may be improved by acting on the contrast key Printer Internal 24 column impact printer for use with ordinary Non Thermal paper pos in Fig 2 2 Thanks to the use of ordinary paper and an ink ribbon running costs are lower and the printout is more legible and longer lasting when compared to printouts obtained by other systems besides being much more resistant to heat The print menu is accessed by pressing the relative key and besides enabling read out printing the menu also allows you to modify print settings and to advance the paper manually so as to facilitate paper roll replacement Rechargeable Battery Pack The instrumentis provided wth a 12VDC 2A power supply pack to charge the internal batteries The socket for connecting the battery charger to the instrumentis shown as item in Fig 2 2 Once the charge is started the display turns on and shows the charge status Serial connector Mini Din 8 pole In of Fig2 2 we find the socket of the serial cable for conneding the instrument to an external probe for example to the draft gauge optional or to the ionization current probe optional Mini USB connector In Fig 2 2 we find the socket of the serial cable for connecting the instrument to a personal computer Sample pump The sample pump located inside the instrument is a DC motor driven diaphragm pump powered by the instrument and is such as to obtain optimal flow of the sampled gas being anal
68. reference pressure is taken like test gas is the same Test result should be considered only indicative 4400 allows the operator to customize the stabilization phase through the following parameter in the stabilization menu WAIT TIME the stabilization phase duration can be set in the 1 99 minutes range As the UNI 11137 1 standard does not prescribe any stabilization duration the factory setting for this value is borrowed from the UNI 7129 standard which requires a minimum stabilization time of 15 minutes The waiting can be interrupted any time by pressing the pe key even in case the interval has not fully elapsed The tightness test performed according to the UNI 11137 1 standard requires the input of some data regarding the piping system and the test conditions as described in the following PIPING VOLUME An accurate tighness test performed acoording to the UNI 11137 1 standard requires to know the piping volume Because this data if often unavailable 4400 splits the test from the beginning into two different paths the first is adequate for pipings having volume smaller than 25 dm liters this is the most usual situation in this case the volume value is not required because through an overestimation the piping is assumed as having a volume of 25 dm The second path requires to input the piping value either directly through the keyboard when know or by a calculation which takes into account the sum of the contributions
69. s carefully remove the sample probe and remote air temperature probe if used from their relative ducts taking care not to get burnt Then carefully disconnect the water trap hoses and sampling probe from the analyzer Switch off the instrument by pressing the On Off key At this point if the instrument has detected a high concentration of CO and or NO a self cleaning cycle will be initiated during which the pump wil draw fresh outside air until the gas levels drop below acceptable values At the end of the cyde lasting no longer than 3 min the instrument will switch itself off automatically 48 IST01530EEJ 019175A0 190411 4 16 5 Flow Chart Flue Gas Analysis When depressed for at least 2 seconds turrs the instrument on 4400 S w SN 00001_ ver 1 00 E instruments A lt gt Adjusts the display contrast WARNING Insert the gas probe in the chimney Or automatically after 10 seconds reir ER gas Date 19 10 10 28Is0 Select the memory position under which the data I ime 18 22 oper Time 18 3HA0 will be sav ed Rep full Name John smith Mode manual Autozero 25 Natural gas L P G Select the fuel of the plant being tested Bat 94 7 Diesel oil Time 11 33 2 Fuel oil Date 09 18 03 Methane Y Autozero cycle end AUTOZERO_ STARTED OPERATOR ID WARNING Starting combustion Select the test operator analysis Setup the printing options cs Or autom
70. sensible efficiency then condensation is taking place lt is referred to LHV Lower Heating Value and can exceed 100 4 12 1 Zoom Menu This menu can only be accessed when the analysis screen is displayed This key is used to view the test data ona complete list or multi page list or to zoom in on displayed text for better reading IST01530EEJ 019175A0 190411 33 4 12 2 Flow Chart Analysis Menu zoom Eff 83 47 Loss16 67 PRefO Auto 001 Ma PREeTO2 Auto 00l tara gt Ref02 Auto 001 toa le pRefO2 Auto 001 toa 4 27 9 3 For each of the screens until now shown the display in O2 reference mode RefO is highlighted can be activated or deactivated by pressing the QO keys 34 IST01530EEJ 019175A0 190411 By pressing the Analysis key once more and starting from any of the above screens the user may proceed as follows Acti ates the Analysis Menu ii Natural gas John smith full u manual Natural gas 2 oil 4 oil Diesel wood Pellets 8 Y OPERATOR ID p1 Mario Rossi g Luigi Bindi PRINT SETUP www uoae auto Duration 120s Print manual ISTO1S3OEEJ 01917 5A0 190411 Select the memory wherein to store the acquired data Select the fuel of the plant being tested Select the test operator Setup the report printing selecting the number of copies and the type of report to print Select the analysis mode automatic or manual If automatic
71. t Flue Gas Analysis 4 17 Measuring the Differential Pressure optional kit IST01530EEJ 01 917 5A0 190411 TABLE OF CONTENTS 5 0 SENSORS 54 5 1 Sensor Arrangement 54 5 2 Sensor types and relevant positioning 54 5 3 Gas sensor life 55 5 4 Gas sensor life 55 5 5 Expandability to 4 sensors 56 6 0 MAINTENANCE 57 6 1 Routine maintenance 57 6 2 Preventive maintenance 57 63 Cleaning the sample probe 57 64 Maintaining the water trap filter unit 57 6 5 Replacing the particulate filter 58 6 6 Replacing the gas sensors 58 6 7 On site recalibration 62 6 7 1 Flow Chart On site recalibration 62 6 8 Replacing the battery pack 65 6 9 Replacing the printer paper roll 66 7 0 TROUBLESHOOTING 67 7 1 Troubleshooting guide 67 8 0 SPARE PARTS AND TECHNICAL ASSISTANCE 69 8 1 Spare parts 69 8 2 Accessories 69 8 3 Service Centers 69 4 IST01530EEJ 01917 5A0 19041 1 1 0 INTRODUCTION 1 1 General Description of the Combustion Analyzer The design of the handheld combustion analyzer 4400 is clean and ergonomic with an extremely dear and user friendly keypad The 4400 immediately suggests just how even the most sophisticated engineering can give life to an incredibly comfortable and easy to use work instrument Devised to analyse flue gases monitor the pollutants emitted and measure environmental parameters 4400 uses two electrochemical cells that provide the oxygen and carbon monoxide values while a third cell
72. t subject to natural deterioration being intrinsically lacking of oxidation processes The electrochemical cell guarantees high precision results in a time interval of up to about 60 minutes during which the instrument can be considered very stable When measurementis going to take along time we suggest auto zeroing the instrument again and flushing the inside of the pneumatic drcuit for three minutes with dean air During the zero calibrating phase the instrument aspirates clean air from the environment and detects the cells drifts from zero 20 95 for the O2 cell then compares them with the programmed values and compensates them The pressure sensor autozero must in all cases be done manually prior to measuring pressure The values measured and calculated by the microprocessor are viewed on the LCD display which is backlit to ensure easy reading even when lighting is poor 4 2 Measurement cells The measurement cells are electrochemical cells made up of an anode a cathode and an electrolytic solution which depends on the type of gas to be analyzed The gas penetrates the cell through a selective diffusion membrane and generates an electric current proportional to the absorbed gas Such current is measured digitalized temperature compensated processed by the microprocessor and displayed The gas shall not be at a pressure such to damage or destroy sensors The maximum estimated allowed pressure is 100hPa gage The response times of the m
73. ted through the a key COMBUSTIBLE GAS consider that the amount of the leakage is strictly related to the nature of the gas under pressure When the tightness of a piping has to be evaluated itis mandatory to specify the family to which the gas belongs City Gas Natural Gas or LP G TEST GAS again the amount of the leakage is related to the nature of the gas under pressure therefore it is mandatory to spedfy the type of the gas used City Gas Natural Gas L P G orair Please note that the gas used for the test could also be different from the gas to be used in the plant and could even be a not flammable gas Once the stabilization parameter has been set the user can proceed with the tightness test Selecting the item Start Test the test pressure required by the standard is shown then a screen with actual pressure applied to the instrument inputs is displayed After having zeroed the instrument and subsequently having charged the piping to a pressure close to the reference values indicated tightness test can be started through the option TEST which actually starts the stabilization phase In the stabilization screen the following values are displayed P Actual pressure measured by the instrument in the selected measurement unit AP 1 Pressure variation in the last minute updated every 10 seconds This value gives a rough indication about the stabilization level reached in the piping system Wait time Remaining time b
74. test records besides draft smoke and ambient CO NO values The memory can also be selected from the Configure Analysis menu The name of the plant can be entered in the Select Memory menu by pressing the right cursor key in the Name field Analysis data is saved by pressing with the SAVE option highlighted in the background If draft smoke and ambient CO NO values hav e been measured these are also memorized Memory Draft Smoke CO NO amb Once a series of test records has been memorized the user can ask the instrument to display the average value The relative analysis report can then be printed via the Print Menu gt Refo2 mem 001 A IR v Mem QA 1EpO Date 19 10 10 25s 0 pate 18 39 3EKOI Name Jerry Smith gt Mem 001 100 gt 1 19 12 10 15 30 Date 19 10 10 2AsO 2 19 12 10 16 00 Time 18 22 3EIALI 3 19 12 10 16 30 Name Jerry Smith Average analysis Meas Conditions Y w RECALL MEMORY Mem 001 16100 1 19 12 10 15 30 pate AWAY 2EISO 2 19 19 10 16 00 Time 18 22 3ElAH 3 19 12 10 16 30 Name Jerry Smith Average analysis Meas Conditions Y Mem 001 7 Loss16 67 pate 19 10 10 2EIsH pate 18 39 3EIAL1 Name Jerry Smith 1 19 12 10 15 30 2 19 12 10 16 00 gt 3 19 12 10 16 30 Average analysis Meas Conditions Y RECALL MEMORY 1 19 12 10 15 30 2 19 12 10 16 00 3 19 12 10 16 30 Average analysis Meas Conditions Y gt RefO2 Men 001 A BI v Save
75. the user can proceed with the tightness test Selecting the item Start Test the test pressure required by the standard is shown then a screen with actual pressure applied to the instrument inputs is displayed After having zeroed the instrument and subsequently having charged the piping with at least 100 hPa the tightness test can be started through the option TEST which actually starts the stabilization phase In the stabilization screen the following values are displayed IST01530EEJ 019175A0 190411 37 P Actual pressure measured by the instrument in the selected measurement unit AP Pressure variation in the last minute updated every 10 seconds This value gives a rough indication about the stabilization level reached in the piping system Wait time Remaining time before the stabilization phase ends Once the stabilization phase is terminated the tighiness test is started This test is performed by observing how the pressure decays in time during a fixed 15 minutes interval as stated in the applied standard During the tightness test phase the following values are displayed P1 Pressure measured at the beginning of the test P2 Pressure actually measured by the instrument AP Pressure variation with respect to the initial value In case the actual pressure is lower than the initial value pressure is decreasing this value has a negative sign Result Reports the test result tight when the pressure drop is gre
76. ting has been chosen the instrument will display the average of the three tests with the possibility of recalling the individual values If desired the user can then print the relative data total complete etc On the contrary if Automatic Printing was selected the instrument will print the test data automatically based on the current print settings without displaying the average test values Caution when in automatic mode Draft Smoke and ambient CO NO measurements must be taken before initiating the flue gas analysis If on the other hand manual analysis mode is chosen flue gas analysis will proceed manually please see relative Flow Chart In this case the print settings and automatic test duration will not be considered At this point manual analysis may commence first waiting at least two minutes until the displayed values stabilize The user can then proceed with data storage if required or print the analysis report directly The latter will be printed in the format set beforehand When all three tests are over the user can recall the average analysis screen containing all the data necessary for compiling the maintenance log of the boiler or plant In both automatic and manual modes all the pollutant values such as CO NO NO can be translated into normalized values referenced to the previously defined O level by simply pressing the button 4 16 4 End of Analysis At the end of the combustion analysi
77. trovalve it will require not to insert the gas probe in the stack In the latter it is important that the sample probe is not inside the stack since during auto calibration the instrument draws fresh air from the environment and detects the zero value of the gas sensors the details of which are then memorized and used for reference during the analysis It is equally important that this phase is performed in a fresh air environment The pressure sensor is also zeroed during auto calibration 4 16 2 Inserting the probe inside the stack When auto calibration is complete the instrument will instruct the user to insert the sample probe that has been previously connected to the relative input on the instrument and the analysis screen will appear automatically In order for the probe to be inserted at the right point within the stack its distance from the boiler has to be twice the diameter of the stack pipe itself or if his is not possible must comply with the boiler manufacturer s instructions In order to position the probe correctly a reliable support must be provided by diilling a 13 16 mm hole in the manifold unless already present and screwing in the positioning cone provided with the probe in this way no airis drawn from the outside during sampling The screw on the cone allows the probe to be stopped atthe right measuring depth this usually corresponds to the center of the exhaust pipe For greater positioning accuracy the user ma
78. ume measure Modify the value of Combustible gas Add tube Add tube i Test gas Subtract tube Subtract tube the highlighted figure Zero volume Zero volume with keys w A w Take one syringe 100 ml of gas gt Volume measure From the piping Add tube then press OK Subtract tube Zero volume Automatically When the volume measurement procedure is comecty terminated eel an The 4400 shows the the piping measured value otherwise it requires to repeat the gas injection with the syringe VOLUME MEASURE Inject the p VOLUME MEASURE Pressure not stable Please wait 42 IST01530EEJ 019175A0 190411 IST01530EEJ 01 917 5A0 190411 Start test Stabilization Piping volume gt Combustible gas Test gas w PIPING VOLUME Vtot 25 0 dm3 ADD TUBE 0 0 dm pMaterial Copper Diameter 20 mm Length 0 0 m Volume measure Add tube Subtract tube Zero volume w ADD TUBE Vtub 0 0 dm Material Copper gt Diameter 20 mm Length 0 0 m w w ADD TUBE Vtub 0 0 dm Material Copper Diameter 2 om Vtot Vtub Volume measure 0 0 dm pMaterial Copper Diameter 20 mm Length 0 0 m Zero volume SUBTRACT TUBE Vtub Material gt Diameter Length Vtub Material Diameter pLength WARNING Volume measure Zero piping volume Add tube Subtract tube gt Zero volume ZERO gt City gas Natura gas Select material with keys vA Steel Copper PE Se
79. y have formed Do not dean the instrument with abrasive ceaners thinners or other similar detergents 6 2 Preventive maintenance At least once a year send the instrument to a SERVICE CENTER for a complete overhaul and thorough internal cleaning E Instruments highly qualified staff is always at your disposal and will provide you with all the sales technical application and maintenance details required The service center will always return the instrument to you as newand in the shortest time possible Calibration is perfomed using gases and instruments comparable with National and Intemational Soedmens Annual servicing is accompanied by a spedfic calibration certificate that is a guarantee of perfect instrument performance as required by UNI 10389 1 besides being indispensable for users wishing to maintain ISO 9000 status 6 3 Cleaning the sample probe When you finish using the sample probe dean it thoroughly as described below before returning it to its case e Disconnect the sample probe from the instrument and from the water trap Fig a b then blow a jet of clean air into the hose of the probe refer to Fig c to remove any residual condensate that may have formed within 6 4 Maintaining the water trap filter unit To remove the water trap just rotate the cover and unhook the filter holder body remove the internal cup and then replace the filter see figure on the side Clean all the filter parts using water only dry the co
80. y insert the probe gradually into the pipe until the highest temperature is read The exhaust pipe must be inspected before carrying out the test so as to ensure that no constrictions orlosses are present in the piping or stack 4 16 3 Flue Gas Analysis After the sample probe has been inserted in the stack and the combustion air temperature probe if used has been inserted in the relative sample manifold if the instrument has not been configured during auto calibration ISTO1530EEJ 019175A0 190411 47 the following data must be configured Memory use this submenu to define the memory in which the test data and dient details are to be stored Fuel the user will be asked to define the type of fuel used by the plant Operator this is where the name of the test operator can be entered Mode by entering this submenu the user can determine the analysis mode manual or automatic If automatic mode is chosen the reading duration of each and every test must be set besides the printing mode manual or automatic When flue gas analysis begins the instrument will perform and memorize the three tests automatically at the respective intervals set at least 120 sec according to UNI 10389 1 At the end of each test the instrument will emit an audible alarm one beep after the first test two beeps after the second test and three beeps after the third test At this point when all three tests are over if Manual Prin
81. yzed Flue Sampling Probe Stainless steel probe with plastic handgrip see of Fig 2 2 The Standard Length of the steel probes is 12 inches 300 mm Other available lengths are 180 mm 750 mm and 1000 mm with adapter cone for the flue hole diameter 8 22 mm A flexible probe is also available wth a 300 mm long tip for measuring inside flues where the fumes picking point is difficult to reach All probes have a nominal outside diameter of 8 mm Connection to an analyzer via a 3 meter rubber hose and replaceable condensate separator and fine dust filter unit see o Fig22 Measurement cells The instrument uses pre calibrated gas sensors of the longdasting FLEX Sensor series for measuring oxygen 02 carbon monoxide CO compensated in hydrogen H2 nitrogen oxide NO nitrogen dioxide NO2 and sulphur dioxide SO2 An automatic internal device dilutes the concentration of CO when the instrument measures high concentrations The diluting system also allows the CO sensor measuring range to be extended up to 50 000 ppm for full scale 8 000ppm sensor The valve for the optional automatic fast autozero lets the operator turn the instrument on with the probe inserted in the flue Up to 4 alams can be programmed with visual and acoustic warning forthe same number of measuring parameters The measuring cells are the electrochemical type The UNI 10389 1 standard prescribes that the instrument must be calibrated once a year by an authorized laboratory to

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