Model 6203 CA-Calc Manual
Contents
1. Error Indications A series of ERR error codes indicate a problem with instrument operation Often the problem has a simple remedy If the ERR code persists contact the factory Press ESC to bypass the error message Error codes are described in Appendix A Using the Sampling Probe Gas and Temperature Measurements Connect the sampling probe to the CA CALC analyzer as described in Chapter 4 Place the Sampling probe through a hole in the exhaust flue following recommendations presented below Placement of the probe is 22 Chapter 5 important and certain considerations must be given when choosing a sampling location To ensure that the gas measurements are not diluted or cooled by outside air place the probe before any draft damper or regulator as illustrated in Figure 8 Tilt the probe tip up slightly so vapor condensing in the sampling tube does not run back to the probe tip and cool the thermocouple tip The sampling probe tip should be placed at the point of highest exhaust gas temperature This means at the base of the flue before heat is lost to the flue sidewalls and towards the center especially for small ducts If the flue stack gas temperature is underestimated the operating efficiency will be overstated When an economizer or air heater is used the flue stack temperature is measured after these devices Important Orient the sampling tube to ensure that the thermocouple tip is ex2. Draft Sensor A differential pressure transducer in the CA CALC analyzer is used to measure draft pressure Water Trap The water trap shown in Figure 2 is used to remove moisture that collects in the sample tubing when combustion gases are sampled The water trap has a two chamber design with a particulate filter Optional Combustion Supply Air Thermocouple Probe A measurement of the Combustion Supply Air TA temperature at the source can be made using an optional thermocouple accessory probe TSI PN 3013003 This probe is connected to the supply air temperature port shown in Figure 1 When a Supply Air temperature probe is not used the supply air temperature is determined from the on board temperature sensor Component Identification 9 Schematic Representation of CA CaLtc Analyzer tall Sampling Probe Electrochemical Gas Sensors Water Trap Flue Gas Temperature Probe Combustion Supply Air Temperature Probe Pressure Transducer Figure 3 Schematic Representation of CA CaLc Analyzer 10 Chapter 3 Chapter 4 Getting Started Supplying Power The CA CALC portable combustion analyzer operates using 4 C batteries or an AC adapter Quality alkaline batteries enable the instrument to operate for at least 24 hours Use of the plug in AC adapter conserves battery life and can be substituted for batteries Installing Batteries Turn t
3. Differential temp Loss Siegert Loss ASME x NOu COu lb MBtu ng PPM mg m3 hPa in H20 mmHz0 mbar CO ratio NOx undiluted Average of samples Sample number NO undiluted CO undiluted Pounds million Btu Nano grams Joule Parts per million Milligrams M Hecto Pascals Inches of water Percent Millimeters of water Millibars Battery life Clear data Review data Save data Light on off Pump on off Printer Zero draft sensor Figure 7 LCD Display and Description of Icons Basic Operation 19 Measurements and Calculations 20 Oxygen Measurement An O electrochemical sensor measures oxygen concentration in the range of 0 to 25 The O measurement is also used to calculate the concentration of carbon dioxide CO in the exhaust and is used in calculations of combustion efficiency and undiluted CO and NO concentrations Carbon Monoxide Measurement Carbon monoxide is measured in the range of 0 to 5000 PPM CO Measurement CO gt calculated from the O concentration in the flue Refer to Appendix B for a description of the calculation NO Measurement Nitric Oxide is measured in the range of 0 to 4000 PPM Flue stack Temperature TS Flue temperature is measured with sampling probe Combustion Air Temperature TA Measurement of c
4. Note For Siegert fuels and fuel parameters to be displayed the fuel heat LOSS selection must be set to qA not LOSS Refer to the section UNITS MENU Option changing units in this chapter The Siegert value for flue loss given the designation qA is used widely in Europe Two coefficients are used in the Siegert formula for flue loss derived from typical fuel compositions These are given the designations A2 and B Fuel Parameter Description A2 Siegert factor fuel specific B Siegert factor fuel specific CO2MX CO maximum F CO F NOx Emission Factors Menu Options 39 The default Siegert coefficient values in your CA CALC analyzer are those used in Germany Siegert coefficients used in other countries may be different reflecting differences in local fuel compositions Figure 25 diagrams the steps in changing the Siegert fuel parameters gt Figure 14 Changing Fuel Parameters for Siegert Fuels LANG MENU Option Use this option to select between the following languages E English D German N Dutch FI Finish I Italian or S Swedish English is the language default initially installed on the instrument When the language is changed instrument settings are automatically changed too Refer to Chapter 4 Default Instrument Settings for more information on this feature 40 Chapter 6 Chapter 7 Setup for Gas Calibration The Calibration Setups
5. 00110 00110 00118 00110 0 001 0 00118 00063 00063 00067 00067 00072 00067 0 00067 0 00072 Ft units Ilb MBtu PPM For those familiar with Method 19 Ft is related to Fd in the following way Ft in units Ibs MBtu ppm Fd in units scf MBtu Ft Fd x b scf ppm Calculations 53 Important Note The Emission Rate factors shown in the table above are always expressed in units of lb MBtu PPM regardless of whether the instrument is configured to display lb MBtu or ng J This is important to recognize if entering your own factors A General Equation for the Combustion of a Simple Hydrocarbon in Air 4x C H j 0 C0 ZH 0 x and y are the number of atoms of carbon and hydrogen in the fuel Calculating CO Max From the Carbon Content moles CO moles CO moles N2 CO gt max x 100 moles CO x moles moles NOS 4x y 3 76 Calculation of Combustion Air Requirement Pounds Air Pound Fuel 11 5C 34 3 H2 02 8 4 3S C H2 O2 and S are the fractions by weight of each chemical constituent of the fuel 54 Appendix B Appendix C Series CA 6203 CA CaLc Combustion Analyzer Specifications Oxygen 02 Sensor Type woeeeeeseesseeeteeeneeenaes Electrochemical RANG Gi rinin 0 25 ACCULACY siete cascreeeercerviccncereesences 40 3 O2 Resolution 0 1 O3 Response TiMe lt 30 seconds to 90 of step change Carbon Monoxide CO Sensor
6. Note To perform your gas sensor calibration you will also need to refer back to Chapter 6 and the section CALIB MENU Option CO NO and O gas sensors can be calibrated periodically to maintain the best accuracy Gas sensors do drift over time depending upon the operating environment and gas exposure history CO and NO gas sensors can lose sensitivity by as much as by 10 per year Since O sensors are calibrated in room air loss in sensitivity poses no real problem However a drift in the zero no Oy present can occur impacting the accuracy when measuring low O concentrations With the proper equipment such as that shown in the figures below it is easy to calibrate your CA CALC analyzer gas sensors However if you wish you may also return your instrument to TSI for a new factory calibration The equipment needed to calibrate individual gas sensors can be purchased from TSI as calibration kits Model numbers for these kits are found in Chapter 2 Unpacking You may also elect to put together your own calibration system Two calibration setups are presented in Figures 26 and 27 A brief discussion of these calibration setups is presented in the following section 41 Demand Flow regulator Sampling probe Probe adapter tube and fitting Calibration gas bottle Figure 15 Calibration with TSI Calibration Kit A TSI supplied calibration kit Figure 15 uses a demand flow reg
7. CO and NO sensors are zeroed At the end of the WARM sequence 45 seconds the pump stops and the draft sensor is zeroed The WARM sequence can be bypassed by pressing the ESC button Do this if a new O calibration and new zeros are not desired 16 Chapter 5 OYA conos NEU ae Model Number NO Fete Ji EA NOw hPa nHn mir O mbar i F C CO NOx Serial Number CA CALC Telos COr CO burg NQ een Error Codes ERR XX i Version Number Warm up Countdown gt Main Data Display Figure 5 Startup Sequence Basic Operation 17 Characters and Display Icons Refer to Figures 6 and 7 that follow These identify the icons and characters found on the Model CA 6203 display The display icons indicate measurements made units or functions performed Some icons are not used with the Model CA 6203 18 OuUs EffCONOu MENU 1 sate ae NA l POND NA M N A pen rey Ox TAN ZN ZN WAN Wan r ANIAN ZIN AN F p TqALossCOrNO2u Ox U SHEHER o g Figure 6 LCD Display Showing Icons Chapter 5 02 CO NO l Eff C02 MENU Loss COr NOxu Oxygen Carbon monoxide Nitric oxide Draft Supply air temperature Efficiency Siegert Efficiency ASME Carbon Dioxide Menu Fuel Flue Temperature Lambda excess air Excess air Degrees F Degrees C NOx
8. Heat losses are per unit weight of fuel Fuel heating value HHV or LHV high heating and low heating respectively This basic method is described in the ASME American Society of Mechanical Engineers Power Test Code 4 1 Note however the calculation of Combustion Efficiency considers only flue losses In ASME PTC 4 1 losses from other sources e g radiation convection are also considered 51 Fuel Parameters for U S Fuels Fuel NATG PROP OIL2 OIL6 Parameters Methane Propane Oil 2 Oil 6 COAL WOOD COKE C carbon 75 81 8 85 84 87 49 94 5 51 8 98 2 MH hydrogen 25 18 18 12 46 9 92 5 2 6 3 1 5 KBTU Ib HHV 23800 21600 19500 18300 13400 9100 16 5 CO2max 11 8 13 8 15 6 16 5 17 19 1 20 1 S sulfur 0 0 1 6 1 40 0 034 0 0 H20 moisture 0 0 0 0 0 12 0 5 Siegert Formula This formula is widely used in Europe to determine flue gas losses qA and efficiency A2 qA Ts Ta date Efficiency 100 qA where qA dry gas losses Ts flue temperature Ta supply air temperature O2 measured volumetric oxygen concentration expressed as a percent A2 B fuel dependent constants The constants A2 and B are based on the composition of combustibles in the fuels In Germany the following prescribed values are provided for common fuels Fuel Parameters for Siegert Fuels Fuel Type A2 B NATG Natural gas 6
9. before being turned on 56 Appendix C TSI Incorporated 500 Cardigan Road Shoreview MN 55126 U S A USA Tel 1 800 874 2811 E mail info tsi com Website www tsi com UK Tel 44 149 4 459200 E mail tsiuk tsi com Website www tsiinc co uk gt France Tel 33 491 118764 E mail tsifrance tsi com Website www tsiinc fr Germany Tel 49 241 523030 E mail tsigmbh tsi com Website www tsiinc de India Tel 91 80 41132470 E mail tsi india tsi com China Tel 86 10 8251 6588 E mail tsibeiling tsicom l am Singapore Tel 65 6595 6388 E mail tsi singapore tsi com wy Contact your local TS Distributor or visit our website www tsi com for more detailed specifications P N 1980472 RevC Copyright 2010 by TSI Incorporated Printed in U S A
10. ia ost daaael dagen ease oe 34 Temperature Calibration cccceeeeeeeeeeteeeceee cette teenieeeas 35 CAL FA MENU Option Setting the Calibration Factor fora Replacement Gas SENSOF eessen 35 COS OMS OF iniae eiio ia ad iiaia iaiia 35 NOSS ONS Of iseina tii ia iiaii diab 36 BAUD Rate MENU Option ccc eet eete eee eete tenance ceee 37 COMM MENU Option Set the Output Communications D VitE te irate ee pal eal iad a aiae 37 FP MENU Option Fuel Parameters escsesescererecrreer 37 LANG MENU ODtion c ccccccecsceeeeeceeeeceeeeeseeseeseessesnesseeeeteaeeaes 40 Chapter 7 Setup for Gas Calibration ssssssssssnnssnnnnnnnnnnnnnnnnnnnnnnnna 41 The Calibration Setups 0 cc eecceesseesseceeeteeeteeeeeeeesaeesneetaeeeaeeas 41 Chapter 8 Maintenance and Troubleshooting us0e 45 Emptying Water Trap c eccceccsccseceeseeeeeeeteeeeieeeieesteenseeeneetiaee 45 Changing the Water Trap Filter eneee 45 Cleaning the Sample Probe 46 Lithium Battery Replacement esseere 46 Replacing a Gas SENSON eect ceeeeeeteeeteeeeteetteeteetteetaee 47 Appendix A Error Codes sssssssussnsnnsnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnna 49 Appendix B Calculations s ssssssssnsnnsnnnnnnnunnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnn 51 Undiluted Gas Concentration Calculation COu NOy NO yw 51 Excess Air Calculations cessive crests ade ieee 51 Calculating Combustion Efficiency for U S Fuels 51 Siegert Formulae serena A e rendition 52 Determining CO2 Using
11. the O Concentration secere 53 Emission Rate Calculations Using Emission Factors 53 Emission Rate Factors miniona ena a a a aani 53 ii A General Equation for the Combustion of a Simple Hydrocarbon IN ANN sssscasiveetaadtavaiieiehtadssaavhbeas eae laatetiatiaw 54 Calculating CO Max From the Carbon Content 54 Calculation of Combustion Air Requirement eee 54 Appendix C Series CA 6203 CA Catc Combustion Analyzer Specifications e nee 55 J TUV Reg No 229 Tested and approved for Measurement of O2 CO and Temperature iii iv This page intentionally left blank Introduction Manual Purpose This manual describes the operation and maintenance of TSI CA 6203 CA CALC portable combustion analyzer Using This Manual Before using your CA CALC combustion analyzer review this manual in its entirety Warnings and Cautions The manual assumes that you have a basic understanding of combustion safety and are thoroughly familiar with the fuel burning equipment being tested If you are using measurements as the basis for equipment adjustments rely on your good judgment and experience together with the measured data This is especially important for safety Remember when adjusting equipment always follow the manufacturer s recommendations WARNING High temperatures and toxic gases are produced when fossil fuels are burned Only qualified individuals thoroughly familiar with operating and adju
12. the SAVE DATA button to save data over the sampling interval Menu Options 31 TIME MENU Option Set Time and Date for Printout Press the ENTER button when the TIME MENU item is displayed Use the ARROW buttons to select the field to be changed The field will blink as it is changed with the right and left ARROW button To change the value use the up and down ARROW buttons Press ENTER to install the new value Press ESC to abort and return to the previous screen Use the DATE option in UNITS to change the month day presentation Time and Date fields CALIB MENU Option select sensor for calibration The CALIB MENU option is used for performing calibrations of the on board sensors When this option is chosen using the ENTER button characters and icons associated with the installed sensor will be displayed one at a time Press an ARROW button and scroll through the options until the desired sensor for calibration appears Press ENTER to begin the calibration process Example Draft Icons below appear one at a time See calibration initiated Chapter 5 for a description of icons Use ARROW a D buttons to choose CAL sensor for ZERO gt Cc calibration Press ENTER to initiate the calibration 32 Chapter 6 O Gas Sensor Calibration The Oxygen O2 sensor is SPAN calibrated in room air whenever the instrument is turned on and allowed to complete the Startup sequence Using the BASE L MENU option also span
13. to select the CO icon and press ENTER Sampling from the room air press ENTER to perform the ZERO calibration When complete connect your CO calibration gas as depicted in Chapter 7 Setup for Gas Calibration Use the ARROW buttons and adjust the CO gas calibration number to match the concentration of your gas bottle Press ENTER to initiate the CO calibration Once complete connect your calibration gas bottle containing both carbon monoxide and hydrogen see note below Use the ARR OW buttons to adjust to the CO bottle concentration under the SPAN CO heading then press ENTER Under the SP AN H2 heading adjust the number using the ARROW buttons to match the hydrogen concentration Press ENTER to start the calibration Menu Options 33 Note Itis possible to do only the CO part of the calibration To bypass the calibration using the combined CO and H bottle press the ESC button after the CO portion of the calibration is complete CAUTION Toxic Gases Familiarize yourself with the toxic properties of the calibration gases by reading the supplied Material Safety Data Sheets MSDS accompanying the gas cylinders Do not perform calibrations in a confined space Make sure calibrations are performed in an area with proper ventilation or under an exhaust hood NO Gas Sensor Calibration From the MENU screen select the CALIB option Press ENTER Use the ARROW buttons to select the NO icon and press ENTER Samp
14. 4 C cell alkaline batteries 1 Operation and Service manual 1980472 Accessories and Replacement Parts Item Part Model Combustion Supply Air thermocouple 3013003 Portable printer kit 801994 Computer cable 8940 Hard side Carrying case 1319319 CO replacement sensor 802014 O replacement sensor 802012 NO replacement sensor 802007 Water trap filters 801947 Calibration Kit O N2 gas and CO 802003 Calibration Kit CO 801999 Calibration Kit NO 801937 Replacement bottled gas CO requires Cal Kit 801941 Replacement bottled gas NO requires Cal Kit 801930 Replacement bottled gas N requires Cal Kit 801980 Bottled gas CO with H requires Cal Kit 801942 This page intentionally left blank Chapter 2 Chapter 3 Component Identification Key components of the CA CALC combustion analyzer and sampling probe are identified in Figures 1 and 2 and under section headings in the text that follows 1 Data buttons 9 Battery cover 2 LCD display 10 Battery cover tab 3 On Off button 11 Port for flue gas thermocouple 4 Control buttons 12 Port for supply air thermocouple 5 Icon buttons 13 RS 232 serial port 6 Magnets 14 Power connection 7 Vent 15 Draft sample port 8 Sensor cover 16 Gas sample port Figure 1 CA 6203 CA CaLc Combustion Analyzer 6 1 Tube retaining fitting 6 Thermocouple connector 2 Probe handle 7 Flexible sample line 3 Position collar 8 Water Trap 4 Sample tube 9 Water tra
15. 6 009 OIL2 light fuel oil 68 007 OIL6 heavy oil 68 007 TGAS Town gas 63 O11 CGAS Coking oven gas 60 O11 PROP propane 63 008 52 Appendix B Determining CO Using the O Concentration 20 9 0O measured CO by volume CO max x 20 9 CO max is the theoretical maximum concentration produced for the fuel used Emission Rate Calculations Using Emission Factors Emission rate expresses the CO and NO concentrations in units of mass of effluent per amount of energy fuel consumed Ib Mbtu or ng J Since fuel energy differs from fuel to fuel emissions expressed in PPM for example must be converted using a fuel specific parameters This is where the Emission Factors F CO and F NO are used The emission rate calculation presented below is described in EPA Method 19 This uses the dry gas factor Fd Dry factors are incorporated into the values found in the Table I below The table values Ft convert the measured concentrations of emission gases CO NOx and SO from PPM to pounds per million Btu of fuel Note The bracketed quantity converts the emission rate to the undiluted value E Cg rd ee undiluted 20 9 O measured where E Emission Rate pounds MBtu of fuel ng J Cg Gas Concentration PPM Ft factor from Table I below O measured Oxygen concentration from flue measurement Emission Rate Factors Factor Nat Gas Propane pil 2 D Bagasse Coke Ft dry 00104 00104
16. C analyzer to that of your computer as described in Chapter 6 MENU Options The factory preset baud rate is 1200 Set the COMM option to COMP so serial data is formatted for output to the computer The alternative is PRNTR indicating output formatted for printer output Press the PRINT button to send data to the computer Default Instrument Settings The CA CALC combustion analyzer uses a number of parameter settings for presenting measured data performing calculations and controlling instrument operation These include the measurement units the fuel used the baud rate and so on When shipped your instrument has factory preset parameter settings and the selection of E English as the Default language When another language is chosen from the language MENU option different settings are automatically installed These are indicated in the table below Specific settings are easily changed as described in Chapter 6 MENU Options However settings are reset to those listed below if the language is changed Factory Defaults and Language Selection Language Selection E Default D FI S N 1 02 co PPM parts per million PPM Draft units Inches H20 mbar Temp units Degrees Fahrenheit Degrees Centigrade Excess Air EA EA 100 1 Effc Loss basis ASME Siegert formula Effc loss units net qA Fuel parameters C H H20 HHV CO2max A2B Fuel list U S Fuel
17. CT NEGLIGENCE TORT STRICT LIABILITY OR OTHERWISE SHALL BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE PRICE OR AT THE OPTION OF SELLER THE REPAIR OR REPLACEMENT OF THE GOODS IN NO EVENT SHALL SELLER BE LIABLE FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES SELLER SHALL NOT BE RESPONSIBLE FOR INSTALLATION DISMANTLING OR REINSTALLATION COSTS OR CHARGES No Action regardless of form may be brought against Seller more than 12 months after a cause of action has accrued The goods returned under warranty to Seller s factory shall be at Buyer s risk of loss and will be returned if at all at Seller s risk of loss Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND LIABILITY which contains the complete and exclusive limited warranty of Seller This LIMITATION OF WARRANTY AND LIABILITY may not be amended modified or its terms waived except by writing signed by an Officer of Seller Service Policy Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our customers our service policy is designed to give prompt attention to any problems If any malfunction is discovered please contact your nearest sales office or representative or call TSI s Customer Service department at 800 874 2811 or 651 490 2811 This page intentionally left blank Contents INtTrOCUCTION a eee nnn 1 Manual PUurp0S sis Aceon een actatin anti EAE A aided ates 1 Using This M
18. ENERGY AND COMFORT Combustion Analysis CA CALC Combustion Analyzers Model 6203 Series Operation and Service Manual P N 1980472 Revision C August 2010 q gt TRUST SCIENCE INNOVATION ru Start Seeing the Benefits of Registering Today Thank you for your TSI instrument purchase Occasionally TS releases information on software updates product enhancements and new products By registering your instrument TSI will be able to send this important information to you http register tsi com As part of the registration process you will be asked for your comments on TSI products and services TSI s customer feedback program gives customers like you a way to tell us how we are doing TSI Incorporated USA Website www tsi com UK Website www tsiinc co uk Germany Website www tsiinc de France Website www tsiinc fr Singapore E mail _ tsi singapore tsi com Manufacturer of TSI AinrLow Instruments and Alnor products P N 2980174 Rev F Copyright 2010 by TSI Incorporated Copyright TSI Incorporated 2002 2010 All rights reserved Address TSI Incorporated 500 Cardigan Road Shoreview MN 55126 USA Fax No 651 490 3824 LIMITATION OF WARRANTY AND LIABILITY effective J uly 2000 Seller warrants the goods sold hereunder under normal use and service as described in the operator s manual shall be free from defects in workmanship and material for twenty four 24 months or the length
19. Tilt the sensor aligning the base pin with the base receptacle and the right pin with the right receptacle Once aligned stand the sensor up and push in When installed properly the sensor will not twist Calibration factor when installing a replacement CO or NO sensor from TSI enter the calibration factors for the sensor as described in Chapter 6 CAL FA MENU Option Left Side Rubber Sensor Cups Receptacles for Sensor Pins Ng Figure 18 Sensor and Sensor Cup Assembly Maintenance and Troubleshooting 47 48 This page intentionally left blank Chapter 8 Appendix A Error Codes Note An Error Code can be bypassed using the ESC button 7 Error in logged data 9 Can t save data to EEPROM 10 Fuel type changed to Natural Gas fuel and LOSS type mismatch 11 An invalid fuel parameter was corrected 12 Model number checksum error 13 TA thermocouple checksum error 14 TS thermocouple checksum error 15 Draft sensor checksum error 16 A D calibration checksum error 17 CO sensor checksum error 18 O2 sensor checksum error 19 NO sensor checksum error 50 O2 zero voltage out of range 51 CO zero voltage out of range 52 COAUX zero voltage out of range 53 NO zero voltage out of range 54 TA sensor zero voltage out of range 55 TS sensor zero voltage out of range 56 Instrument temperature out of range 57 Draft zero voltage out of range 58 Draft ga
20. Type sssscssrssirirs Electrochemical RANG Gis vesciicasscnectecmecnncivertess 0 5000 ppm ACQUIACY iunii naina 0 100 ppm ppm or 10 of reading 100 5000 10 ppm or 5 Resolution 1 ppm Response TiMe ee lt 30 seconds to 90 of step change Sampling Probe Hose length 7 5 std 2 4 m Probe diameter c cesses 5 16 0 8 cm Nitric Oxide NO Sensor Type sssscsirssrrss Electrochemical Ranges aioa n asa a 0 4000 ppm AccUra Cyin 0 100 ppm ppm or 10 of reading 100 4000 10 ppm or 5 Resolution 1 ppm Response TiMe lt 30 seconds to 90 of step change Flue stack Temperature RANGE cecccccecccicieceieieerorceeeens 0 1000 C Resolution oo eee ceeeteeteeteees 1 C AGC CUA GS norni ii 2 C or 5 of reading Supply Air Temperature Probe RAN GC soane ann 40 150 C Resolution oo eee eeeeeeeeteeeee tees 1 C ACCUIACY direncini 1 C or 1 Draft Range siiani 30 H 0 80mbar Resolution noscere 0 01 H20 ACCUFICY dioiii in 1 rdg or 01 H20 zeroed Specifications are subject to change without notice Specification giving lowest accuracy is applied 55 External Dimensions 6 x 10 x 2 5 Communication Interface WW o T TT Serial 1200 19200 selectable Batteries 4 C cell alkaline batteries gt 24 hours pump on Use only TSl supplied adapter Lithium Note These specifications assume the instrument is allowed to stabilize at the operating temperature
21. and DVAL to values on the calibration sheet using the up and down ARROW buttons Follow each change by pressing the ENTER button Figure 12 shows the steps Pressing ESC takes you out of the entry sequence but keeps values which were saved with the ENTER button Once complete review entered values by stepping through the calibration factor screens using ENTER Menu Options 35 Use the ARROW buttons to find the CAL FA MENU option Press the ENTER button MENU CO icon C A L F A co Choose the CO gt C A L i F A icon using the a D ARROW buttons and press ENTER Dy AVAL 0823 BVAL CAL FA 4500 CO CVAL 8342 lt q D DY a D Use ARROW buttons to change AVAL BVAL CVAL and DVAL calibration factors Press the ENTER after changing each value Complete return with the ENTER E D button followed by ESC Figure 12 Setting the Calibration Factor NO Sensor After installing your new sensor as described in Chapter 8 Maintenance and Troubleshooting find the NO calibration factor sheet Use the ARROW buttons in the MENU option and find CAL FA Press ENTER Use the ARROW buttons and select the NO sensor icon press ENTER Adjust the number displayed to match the value on the calibration sheet Press ENTER to finish Press the ESC button to return to the Data Display 36 Chapter 6 BAUD Rate MENU Option Baud rate can be set to match your c
22. anual Asis meginat aanmaak i anita 1 Warnings and Cautions 0 0 cece ceeeeecteeseeeeeneecneeseeesneetneeeaaes 1 Chapter 1 Instrument Description sssssssssssnssnnsnnnnnnnnnnnnnnnnnnnnnnnnnan 3 CA 6203 CA CaLc Combustion Analyzer Measurements and Calculations ardits ini ee eating 3 Chapter 2 Unpacking eee eee 5 List of Standard COMPONENS 0 0 cece eee eeee eee e tee teee tee eee eee 5 Accessories and Replacement Parts serere 5 Chapter 3 Component Identification ssssssssssnnssnnsnnnnnnnnnnnnnnnnnnnnnan 7 The Gas Sensor armeou i e Mea diale 8 The Sampling Probe iiss ein eia ai a E 9 Flue Probe Thermocouple sssssisssrissiieririirisrresiisrirrieninrieneennre 9 On Board Temperature Measurement 9 Diaphragm P UMD ai aieiaa aa aiea aeea E iae 9 Draft Senso sis iis nhetsttevdia nti aa a i EAA EEr E aa 9 Water TraPiinsanodpkiiiisopaton tena a a aa aai 9 Optional Combustion Supply Air Thermocouple Probe nsss 9 Schematic Representation of CA CALC Analyzer 10 Chapter 4 Getting Started cee 11 SUPPIVING POWER rieira aed heeded 11 installing Batteries 3 6 ccs wien ne deriievhavemiitiet inti 11 Connecting the Sampling Probe cece teeter eeeeteeeeteeeee 11 Connecting the Optional Combustion Supply Air Temperature PROD G aifieiertewlei ei eens aud ie e A a aiea 12 Connecting the Optional Portable Printer 12 Connecting to a COMPUTED serere 12 Default Instrument Settings eenen 13 Factory Defaults an
23. be and sampling line and over time may contribute to a blocked flow path 1 Remove the water trap by separating the sample tube from the tube stub on each end of the trap 2 Rinse the tubing allowing the water to drain from the probe end When the water is clear discontinue the rinse Orient the probe and tubing so excess water drains from the sample lines 3 Allow adequate time for the interior of the probe to dry Replace the water trap making sure the water trap is oriented properly The filter must be toward the instrument Lithium Battery Replacement The lithium battery supports measurement data saved in memory Typical battery life is three years An ERR code 63 indicates a low lithium battery To replace the battery open the battery compartment and remove the C cell battery holder Find the AA lithium battery after removing the white foam battery retainer Replace the battery in the correct plus minus orientation Replace the white foam retainer C cell holder and battery cover 46 Chapter 8 Replacing a Gas Sensor Remove the sensor cover identified in Figure 1 8 From the left side pry back the black rubber sensor cups to expose the gas sensors Do not separate any fittings connected to the rubber cups To remove a senor grasp the sensor and lift straight up When installing a sensor note the orientation of the sensor pins at the bottom of the sensor and the orientation of the receptacles in the instrument
24. d These are the Fuel Parameters In your CA CALC analyzer U S fuel parameters are the carbon and hydrogen content moisture content sulfur content and maximum CO CO2MX Menu Options 37 Press ENTER button from the Data Display screen cab Find FP using the ARROW buttons a gt Press ENTER to access the fuel parameter list Find the parameter to change using the ARROW buttons AS Change the parameter value using the ARROW buttons Press the ENTER button to accept the new value Press ESC to abort The example to the right is for changing the hydrogen fuel percent Figure 13 Fuel Parameters for U S Fuels 38 Chapter 6 Refer to the diagrams Figures 13 and 14 and tables below for information on viewing and changing fuel parameters Your CA CALC analyzer has parameters for seven common U S fuels in instrument memory Fuel parameters for these fuels can be changed if you know for example that your fuel has a different composition than that stored The instrument fuel parameters values are presented in Appendix B with additional technical information Fuel Parameter Description C carbon by weight H hydrogen by weight H20 moisture content by weight S sulfur by weight CO2MX CO maximum KBTU Heating value in kiloBTUs BTU 1000 F CO F NOx Emission Factors FP Fuel Parameters for Siegert Calculation Siegert Fuel Parameters
25. d Language Selection ceceeeeeeeeeeees 13 Chapter 5 Basic Operation ssee ee 15 Buttons and Button Operations ccc cceeeeeeeeeecee eee eeeeeeeecees 15 SCG UU o SEE A E PA attain anthi natant tard naee 16 Characters and Display ICONS cceeceseeeeeceeeseeeetteeneeeeeees 18 Measurements and Calculations erer 20 Data Display Viewing Measurements and Calculations 22 Error Indications ene ania ri it 22 Using the Sampling Probe cece eects eeeeeeteeeneeeteeceeaes 22 Making a Draft MeaSUreMe nt cece cece teeeteeeeeeetteetteeeteeecets 24 Printing to the Portable Printer and to a Computer 24 Handling D ata sitions taeda diesen a neat ve 27 Chapter 6 MENU Options see 29 BASE L MENU Option Update Sensor Baselines c0008 30 FUEL MENU Option Select Fuel aseeseen 30 FP MENU Option Fuel Parameters 0 cccccccceeeeeeeeeeeeeteees 31 UNITS MENU Option changing units 31 INT SA MENU Option Sampling Interval for Saving Data 31 TIME MENU Option Set Time and Date for Printout 32 CALIB MENU Option select sensor for calibration e 32 Ov Gas Sensor Calibration oo ccccccccccccessssssseseesensecsesseneeeeeees 33 Calibration of the CO hydrogen compensated Sensor 33 Calibration Steps t tatncinadatiteerien a aata naia 33 NO Gas Sensor Calibration ssseeseeeieisrieeiiriserierirrieeieess 34 Draft Cali Paton rcs ces ataistevs sai teeegcale apa
26. de Excess air Stack Flue loss qA Combustion efficiency Differential temperature NO CO undiluted NO undiluted CO index NO undiluted Emission Rates CO NO The Model 6203 is supplied with a sampling probe having an in line water trap and particulate filter The Model 6203 operates using either an AC power supply or C size batteries The Model 6203 stores individual data samples up to 100 and prints the data to a portable printer or computer Stored data can be saved over a user defined interval and averaged The Model 6203 has a variety of standard fuels and enables you to modify the fuel parameters or install your own user defined fuel Loss and efficiency are calculated from standard ASME heat loss calculations or using the Siegert formula refer to Appendix B 4 Chapter 1 Chapter 2 Unpacking Carefully unpack your CA CALC combustion analyzer and accessories from the carrying case Check the individual parts against the list of components in the table below If items are missing or damaged notify TSI immediately List of Standard Components Qty Item Component Part Model 1 Series CA 6203 CA CALC combustion analyzer 1083618 1 Sample probe with water trap draft line and 801989 temperature 1 Universal Power supply 7 2 V with assorted plug 2182003 types
27. dows operating system program Look for HyperTerminal in the Accessories folder In HyperTerminal use the Capture Text option from the Transfer menu for recording instrument data Your instrument comes configured with the following communications protocol Communications Protocol Baud rate 1200 default Data bits 8 Parity None Stop bit 1 Flow None windows and Excel are a registered trademarks of Microsoft Corporation Basic Operation 25 DATE 01 01 06 TIME 15 00 18 Fuel Nat Gas Fuel Parameters C 75 H 25 CO2MxX 11 8 KBTU 23 8 NOx TS Draft 0 01 inH2O CO2 8 4 Lambda OVER Effc 84 LOSS 16 Figure 9 Example Printout Chapter 5 Handling Data Saving Data S Up to one hundred 100 separate measurements can be made and saved to the instrument memory as data Samples Press the SAVE DATA button located below the SAVE DATA icon at the bottom of the display When SAVE DATA is pressed measurements are sampled and averaged over the interval set in the INT SA MENU option described in Chapter 6 As data is sampled the sample number is displayed and the save data icon blinks Note The pump turns off while the draft is measured and saved CLEAR Data X While in the Data Display screen press and hold the CLEAR DATA button for three 3 seconds to erase all saved data from the instrument memory The button must be released when zero is displayed If the button is
28. els NATG fuel is selected PROP 4 D DIL2 4 DIL6 4 CGAS 4 TCAs USER Figure 11 FUEL Options 30 Chapter 6 FP MENU Option Fuel Parameters See later UNITS MENU Option changing units It is possible to display data in different measurement units as indicated in the table below Optional Units Measurement UNIT Options TEMP temperature Degrees F Degrees C GAS for CO NO NO PPM mg m lb Mbtu ng J concentrations PRESS draft In H20 mbar hPa mmH20 LOSS flue gas heat loss Loss ASME gA Siegert Excess Air EA Lambda DECIMI Periods or commas for printing DATE Date format MM DD or DD MM for printing To change units press the ENTER button from the Data Display screen Using the right left ARROW buttons find UNITS from the MENU options and press ENTER Continue using the right left AR ROW buttons to find the measurement for which units are to be changed Use the up down ARROW buttons to select the desired unit and press ENTER Use ESC when complete to return to the Data Display screen INT SA MENU Option Sampling Interval for Saving Data This option enables you to change the sampling interval over which data is averaged and saved Select this option using the ENTER button Use the up and down ARROW buttons to choose the sampling interval from the following 1 5 10 15 20 25 and 30 seconds Press ENTER to select the interval Use
29. he combustion analyzer over and remove the battery cover by lifting up and out on the battery cover tab shown below Remove the old batteries Note Itis not necessary to remove the battery holder when removing or y installing batteries Best results are obtained if the batteries opposite the contact springs are removed first Install four new C cell batteries noting the battery orientation depicted on the base of the battery holder Install spring side batteries first Connecting the Sampling Probe The sampling probe depicted in Figure 2 is connected to the instrument by pushing the brass sample and silver draft connectors over the ports on the instrument Refer to the figures below showing the proper connection of the probe tubes to the instrument sample ports Note that the thermocouple connector can be inserted only one way The thermocouple connector is oriented with the large spade to the right Do not force the connector 11 Sample Connector Brass Draft Connector Silver Figure 4 Sampling Probe Connections Connecting the Optional Combustion Supply Air Temperature Probe A type K thermocouple probe may be used to measure the temperature of the air supplied to the burner Connect the optional supply air thermocouple see Accessories and Replacement Parts to the supply air thermocouple port depicted in Figure 1 The thermocouple connector can be inserted only one way large spade to the right Do not f
30. he draft port Adjust the negative calibration pressure value using the ARROW buttons and press ENTER Once the calibration is complete use the ESC button to return to the main Data Display screen Temperature Calibration Calibration of the flue and ambient thermocouple sensors is not recommended Thermocouples are very repeatable and even if replacement of a sampling probe is required or a combustion air temperature probe is purchased as an accessory it is unnecessary to calibrate it Thermocouple accuracy can be improved for a specific temperature range if a calibration is preformed in that range You will need to provide an accurate temperature reference Refer to the steps below if calibration of a thermocouple is desired Calibration Procedure Select the CALIB MENU option Select the appropriate thermometer icon in the CALIB screen using the ARROW buttons Install your sampling probe thermocouple or accessory thermocouple at the appropriate TS or TA connector Press ENTER and set the calibration temperature to that of your supplied standard Bring your thermocouple to the entered temperature and initiate the calibration by pressing ENTER CAL FA MENU Option Setting the Calibration Factor fora Replacement Gas Sensor Install your new sensor as described in Chapter 8 Maintenance and Troubleshooting CO Sensor Find the Calibration Factor sheet Use the MENU option CAL FA and press ENTER Change the AVAL BVAL CVAL
31. held longer than three 3 seconds nothing is cleared To clear the last Sample only release the CLEAR data button before the end of the countdown during 3 2 or 1 REVIEW Data Samples g Press the REVIEW DATA button briefly to recall saved Samples The number of the last Sample appears Select the specific data Sample you wish to view using the ARROW buttons and press ENTER When the Sample number is displayed use the ARROW buttons to review the different measurements Printing To print individual saved Samples press the PRINT button while the saved Sample is shown To print all saved Samples hold the PRINT button down until a countdown from three 3 begins Release the button at zero 0 and all saved Samples are printed Averaging Saved Samples To average the last three 3 saved Samples press and hold the REVIEW DATA for a couple of seconds The screen blanks during this interval When averaged the X bar icon appears indicating that the data presented is an average of the Samples Data averaging works only from the main Data Display screen Basic Operation 2T 28 This page intentionally left blank Chapter 5 Chapter 6 MENU Options The Series 6203 CA CALC instrument has a variety of user selectable parameters available as MENU options The user selectable MENU options are shown in the schematic below Press ENTER to access the MENU options from the Main Data Display screen View the MENU options b
32. in calibration out of range 59 O2 span baseline voltage out of range 60 Error in CO sensor present test 61 Error in COAUX sensor present test 62 Error in NO sensor present test 63 Lithium battery voltage is low 64 TA sensor gain factor out of range 65 TS sensor gain factor out of range 66 NO sensor gain factor out of range 67 CO sensor A_VALUE out of range 68 CO sensor B_VALUE out of range 69 CO sensor C_VALUE out of range 70 CO sensor D_VALUE out of range 71 Instrument temperature sensor offset factor out of range 72 AtoD converter gain factor out of range 73 Pump vacuum out of range 74 or higher Internal program error contact TSI 49 50 This page intentionally left blank Appendix A Appendix B Calculations Undiluted Gas Concentration Calculation CO NO NO 20 9 20 9 0 measured GASundiluted GASmeasured PPM x Excess Air Calculation 0 CO 2 x 100 20 9 0 CO 2 Excess Air Another expression of excess is Greek letter Lambda also used The relationship between EA and Lambda is shown below EA 100 A 1 Calculating Combustion Efficiency for U S Fuels Net Combustion Efficiency Effic Net m Combisionbthiciensy 100 eo OO i fuel heating value flue heat losses heat loss from dry gas heat loss due to moisture from burning hydrogen heatloss due to moisture in fuel heat loss from the formation of CO
33. ling from the room air press ENTER to perform the ZERO calibration When complete connect your NO calibration gas as depicted in Chapter 7 Setup for Gas Calibration Use the ARROW buttons and adjust the NO gas calibration number to match the concentration of your gas bottle Press ENTER to initiate the NO calibration Draft Calibration Span calibration of the draft sensor is normally not required The draft sensor should be routinely zeroed however using the DRAFT ZERO button This is especially important prior to making measurements at low draft pressures When zeroing make sure the sample probe is disconnected or that the probe is not in the flue Calibration Procedure Required An apparatus to provide stable calibration pressures of between plus 10 30 inches of water 25 75 hPa and stable calibration pressures of between minus 10 30 inches of water minus 25 75 hPa From the Main Data Display screen press the ENTER button Select CALIB from the MENU options presented using the ENTER button Select the draft icon from the icons displayed using an ARROW button and press ENTER Begin the calibration by pressing the ENTER button to perform a ZERO calibration When the zero is complete use the arrow buttons to adjust your positive supply reference pressure Connect 34 Chapter 6 your positive pressure to the draft port and press ENTER Once the positive calibration is complete connect your negative pressure reference to t
34. ncentration NO is an expression of the total oxides of nitrogen in the flue gas stream NO combines NO and the theoretical NO concentration estimated at 5 of the NO concentration NO is not measured NO Undiluted Nitric Oxide concentration xu Calculation of the NO concentration undiluted by excess air This calculation requires a measurement of the O concentration and the measurement of the NO concentration Refer to Appendix B Draft Draft pressure is measured with the sampling probe inserted in the flue The draft measurement is referenced to room pressure Basic Operation 21 Data Display Viewing Measurements and Calculations Measurements and calculations are presented in the Data Display screens The Data Displays appear once the Startup sequence is complete illustrated earlier in Figure 5 Data appears on three lines with an icon indicating the measurement or calculation presented above or to the left of the data Units are presented on the right side Data are viewed using the ARROW buttons in groups of two or three The table below shows the order of the data displayed together in vertical columns Use the right ARROW button to scroll through the data as shown below Order of displayed measurements and calculations ARROW button gt O2 Draft Combustion Air Efficiency CO INO NO Temperature CO Fuel Flue Excess CO INO NOw Type Temperature Air CO Differential Loss CO Temperature
35. of time specified in the operator s manual from the date of shipment to the customer This warranty period is inclusive of any statutory warranty This limited warranty is subject to the following exclusions a Batteries are warranted for 90 days from the date of shipment to the customer Electrochemical gas sensors are warranted for a period of twelve 12 months from the date of shipment to the customer b Parts repaired or replaced as a result of repair services are warranted to be free from defects in workmanship and material under normal use for 90 days from the date of shipment c Seller does not provide any warranty on finished goods manufactured by others or on any fuses batteries or other consumable materials Only the original manufacturer s warranty applies d Unless specifically authorized in a separate writing by Seller Seller makes no warranty with respect to and shall have no liability in connection with goods which are incorporated into other products or equipment or which are modified by any person other than Seller The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated herein NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE TO THE EXTENT PERMITTED BY LAW THE EXCLUSIVE REMEDY OF THE USER OR BUYER AND THE LIMIT OF SELLER S LIABILITY FOR ANY AND ALL LOSSES INJURIES OR DAMAGES CONCERNING THE GOODS INCLUDING CLAIMS BASED ON CONTRA
36. ombustion air temperature is determined using the temperature probe accessory TSI PN 3013003 In the absence of this probe the combustion air temperature is assumed to be the instrument temperature and determined from a temperature sensor in the instrument case AT Temperature Difference The flue stack temperature minus the combustion air temperature Excess Air or Lambda A Calculations of these values are found in Appendix B Loss ASME based heat loss from the hot gases exiting the flue stack Includes latent heat loss from the formation of water vapor See Appendix B Chapter 5 qA Heat loss using the Siegert formula See Appendix B Efficiency Combustion efficiency expressed as a percent Calculated as 100 percent minus ASME heat loss Loss described earlier Also see Appendix B y Siegert Efficiency Combustion efficiency expressed as a percentage Calculated as 100 percent minus QA Also refer to Appendix B CO Undiluted Carbon Monoxide Concentration Calculation of the CO concentration undiluted by excess air This calculation uses a measurement of the O concentration together with the CO measurement Refer to Appendix B CO CO Ratio Ratio of CO to CO See Appendix B NO Undiluted Nitric Oxide Concentration Calculation of the NO concentration undiluted by excess air This calculation requires a measurement of the O concentration together with the NO measurement Refer to Appendix B NO Co
37. omputer or portable printer Your instrument is delivered with a default baud rate of 1200 to match the printer Baud rate values are displayed in the BAUD rate MENU option divided by 1000 The following baud rates can be set 1 2 1200 2 4 2400 4 8 4800 9 6 9600 19 2 19200 To set the baud rate select BAUD from the MENU option using the ENTER button Step through the BAUD rates using the ARROW buttons and choose the desired value with the ENTER button Use the ESC button to return COMM MENU Option Set the Output Communications Device Your CA CALC analyzer transfers current or saved data to a serial printer or computer The COMM MENU option is used to select the device that you want to communicate with Failure to select the correct device may cause incorrect characters to appear on your printout or computer file COMM options are COMP and PRNTR for computer and printer respectively Set the device COMM from the MENU options using the ENTER button Use the ARROW buttons and choose the desired option followed by pressing the ENTER button Use the ESC button to return FP MENU Option Fuel Parameters U S Fuel Parameters Note For U S fuels and fuel parameters to be displayed the fuel heat LOSS selection must be set to Loss not qA Refer to the section UNITS MENU Option changing units in this chapter For calculations of flue losses maximum COb gt fuel composition and fuel heat content are use
38. orce the connector When the optional Supply Air Temperature Probe is not used supplied combustion air temperature is determined from the instrument temperature using an on board sensor Connecting the Optional Portable Printer Find the printer interface cable included with the optional portable printer For the serial printer connect the large 9 pin connector on the cable to mating connector on the printer Connect the opposite end to the instrument s RS 232 communications and printer port See Figure for port location The printer and CA CALC combustion analyzer have both been factory set for a baud rate of 1200 If baud rates are not matched the printer will print random characters question marks or asterisks Printer settings are described in the printer manual along with illustrations identifying the correct DIP switch configuration To set the CA CALC baud rate and device settings refer to Chapter 6 MENU Options Connecting to a Computer Use the optional computer interface cable Model 8940 to transfer download data serially from the CA CALC analyzer to a computer Your printer cable will not work for downloading to the computer Connect the 12 Chapter 4 large 9 pin connector on the computer interface cable to the 9 pin serial connector on your computer Connect the opposite end to the instrument s RS 232 communications and printer port See Figure 1 for port location Set the baud rate of the CA CAL
39. p filter 5 Probe tip with thermocouple Figure 2 CA CaLc Sampling Probe Components The Gas Sensors The CA 6203 CA CALC analyzer uses three gas sensors for measuring oxygen O2 carbon monoxide CO and nitric oxide NO CO and NO sensors are capable of operating from two to three years The O sensor typically lasts one year Best accuracy is obtained by routine user calibration automatic for the O sensor Calibrated replacement CO and NO sensors are also available from the factory 8 Chapter 3 The Sampling Probe Your combustion analyzer comes equipped with a sampling probe depicted in Figure 2 A thermocouple extends to the end of the sampling tube for making flue temperature measurements Two flexible sampling lines are used for gas sampling and draft measurement The sampling tube is removable for cleaning Flue Probe Thermocouple The flue temperature TS is measured using a Type K probe which extends through the sampling tube to the probe tip The thermocouple probe measures temperatures up to 1000 degrees C 1800 degrees F On Board Temperature Measurement Your CA CALC analyzer uses an on board temperature detector to provide the Combustion Supply Air TA temperature when no supply air accessory probe is present Diaphragm Pump The CA CALC analyzer samples exhaust gases from the flue and delivers them to the electrochemical sensors using a diaphragm sampling pump Typical pump life is 5000 hours
40. posed directly to exhaust flow see Figure 8 below 2 5 cm min 1 Sampling probe 3 Exhaust flue 2 Draft regulator 4 Hot exhaust gases Figure 8 Sampling Probe Location Basic Operation 23 Cautions Hot probe When removed the sampling probe will be extremely hot Avoid touching the probe tip and avoid placing the probe on or near plastic materials such as the instrument case These will melt Maintain a minimum 2 5 cm clearance between the probe handle and position collar when the probe is mounted in flue Empty Water Trap Watch the water trap and empty it frequently to prevent the possibility of flooding the instrument See Chapter 8 for instructions Making a Draft Measurement U Use the DRAFT button to the right of the DRAFT button indicator to make draft measurements When the DRAFT button is pressed the sampling pump turns off and the draft measurement is displayed and updated each second Zeroing the Draft Sensor For the most accurate draft reading the draft sensor must be zeroed prior to the draft measurement To zero the draft sensor remove the sampling probe from the flue or separate the sampling tube from the draft port Press the ZERO draft button When ZERO is displayed the draft sensor is zeroed Saving Draft Whenever a sample is saved using the SAVE DATA button a draft reading is taken For this to occur the pump is automatically turned off and a few seconds are allo
41. ps 2 Remove the probe side end cap by pulling outward with a twisting motion 3 Pour out the water and replace the end cap Re install the trap Important Make sure the water trap is oriented so that end cap 1 below is toward the instrument Changing the Water Trap Filter Identify the water trap filter refer to Figure 17 This filter is designed to remove soot particles before they contaminate the instrument The filter can be removed for cleaning or replacement by following these steps 1 Remove the instrument side end cap by pulling it out with a twisting motion 2 Grasp the filter using a needle nose pliers and pull it out 3 To clean the filter remove the bulk of the soot by tapping the filter The soot may be removed by rinsing with water or isopropyl alcohol The effectiveness of the rinse depends on the soot composition is it dry or oily Avoid rubbing which may drive contaminates into the filter causing permanent plugging 45 4 Whether cleaned or replaced install the filter by pushing it over the stub in the filter body then replace the end cap Instrument side end cap First chamber Probe side end cap Polycarbonate trap body Second chamber Plastic filter Maximum water level 1 N a o WY 2 Figure 17 In line Water Trap Cleaning the Sample Probe Cleaning may be necessary in high soot environments Soot accumulates in the steel sampling tu
42. s Siegert Fuels Fuel Natural Gas Natural Gas Baud Rate 1200 1200 Sampling interval 1 second 1 second Communications Printer format Printer format Time MM DD YY DD MM YY Getting Started 13 14 This page intentionally left blank Chapter 4 Chapter 5 Basic Operation Buttons and Button Operations ON OFF Control Button Turns the instrument on and off Ole The ENTER Control Button Press the ENTER button to execute a command such as selecting a menu item ESC The ESC Control Button Used to return to the previous screen or cancel a process ARROW Control Buttons Use the Left and Right arrow buttons to step between options Use the Up and Down arrow buttons to change number values Button Indicators sly Ca U oy Ke Back Light ON OFF Pump ON OFF Print Make draft measurement Zero draft transducer Select fuel 15 Data Buttons Xx Clear stored data g Review stored data 5 Save data Startup Remove the sampling probe from the flue or disconnect the sample tubing from the sampling port Press the ON OFF button Refer to Figure 5 showing screens displayed during the start up sequence If no errors are detected the Main Data Display screen appears when the sequence is complete Error codes are presented in Appendix A ESC will bypass the error messages While the WARM screen is displayed the O sensor is automatically calibrated using ambient air and the
43. s the O sensor Additional calibration is generally not required Calibrating the O sensor is done to determine a new zero value no O2 present for the sensor This is done if a drift in the sensor zero value is suspected Select CALIB from the MENU options using the ENTER button Select the O icon from the icons displayed using an ARROW button and press ENTER Attach the zero gas nitrogen N to the sampling probe as described in Chapter 7 Setup for Gas Calibration When ready press ENTER to begin the zero calibration Once complete the SPAN calibration screen appears The O concentration can be adjusted using the ARROW buttons If room air is used as the calibration gas use the value displayed initially 20 9 Press the ENTER button to begin the SPAN calibration Once complete use the ESC button to return to the Data Display screen Calibration of the CO hydrogen compensated Sensor The presence of hydrogen gas H produces a false signal on electrochemical CO sensors The CO sensor in your CA CALC analyzer has a second internal sensor that detects the H concentration and enables the instrument software to subtract the error caused by the presence of hydrogen gas You can elect to calibrate using both the CO and Hy or calibrate with CO only In the second case the sensor retains the previous correction for Hp Calibration Steps From the MENU screen select the CALIB option Press ENTER Use the ARROW buttons
44. sting fuel burning equipment should use gas measurements for the purpose of making equipment adjustments Note The CA CaALc analyzer is not intended for use as a continuous monitor Notes Best results are obtained if the CA CALC combustion analyzer is allowed to stabilize at the temperature of the test environment before using To reduce sensor exposure to gas and to reduce build up of water vapor in the sampling lines and water trap turn the pump off when not making measurements This page intentionally left blank Chapter 1 Instrument Description The Model CA 6203 CA CALC combustion analyzer is used to evaluate the performance of burners in boilers furnaces and hot water tanks The Model CA 6203 has sensors for the direct measurement of combustion gases O2 CO NO combustion gas temperatures and draft pressure The Model CA 6203 performs a complete list of combustion and emission parameters for a variety of system performance evaluations Different units and different fuel types are readily selectable CA 6203 CA CaLc Combustion Analyzer Measurements and Calculations Measurement Sensor Oxygen concentration O electrochemical Carbon monoxide CO electrochemical Nitric oxide NO electrochemical Flue temperature Thermocouple Supply air temperature On board sensor or Thermocouple probe Draft pressure Pressure transducer internal solid state Calculations CO Carbon Dioxi
45. ulator to supply gas to the CA CALC analyzer in response to the draw of the instrument sampling the pump If a conventional regulator and valve are used Figure 16 the setup requires a tee to a bleed off extra gas This prevents a forced flow at the instrument inlet The bead type flow meter depicted in the figure is used to verify there is extra flow 5 to 2 L min recommended Extra flow is required to prevent room air from being drawn in diluting the sample 42 Chapter 7 Standard Regulator and Valve Probe Adapter Tubing and Filling l Sample Probe Flow Meter indicating 5 to 2 lpm Calibration Gas Cylinder Figure 16 Alternative Calibration Setup Setup for Gas Calibration 43 44 This page intentionally left blank Chapter 7 Chapter 8 Maintenance and Troubleshooting For additional troubleshooting information please visit TS l s website http combustion tsi com Emptying Water Trap Refer back to Figure 2 showing the water trap in the sample line and to Figure 17 Liquid water forms in the first chamber of the water trap as gases are sampled from the flue The water trap is designed so even when shaken or when its orientation is changed water does not pass to the second chamber The water level must remain below the level depicted in the figure however To empty the water trap 1 First separate it from the sampling tube by pulling the tube ends off the barbs on the end ca
46. wed for the draft reading to stabilize Draft is recorded at the end of the data sampling interval Printing to the Portable Printer and to a Computer 24 Printing to the Portable Printer Instrument data can be output to the optional portable printer through the RS 232 serial port Refer to Connecting the Optional Portable Printer in Chapter 4 Chapter 5 To print the information on the Data Display press the PRINT button to the right of the print button icon The printer responds immediately producing a printout of the current data An example of this printout is shown in Figure 9 Saved data can be printed too Hold the P rint button down until a countdown from three 3 begins Release the button at zero 0 and all saved data is printed Printing individual saved data samples is described in the next section Handling Data Printing to a Computer Use the PRINT button to output data to a computer as well as to the portable printer Refer to Connecting to a Computer in Chapter 4 Data transferred to a computer is the same as that output to a printer see Figure 9 however it is formatted differently and uses the Windows character set rather than DOS characters You will need to set appropriate COMM MENU option before sending data to the computer Refer to the Chapter 6 MENU Options Data can be downloaded to a terminal emulator program such as the HyperTerminal which accompanies the Win
47. y using the right left ARROW buttons Once the screen of interest is displayed press the ENTER button again to choose the MENU option Use up down buttons to change values Refer to Figure 10 which shows the MENU options Press the ENTER button from the Main Display to enable the Menu options Press ESC to return to Data Display Use ENTER to select an option Figure 10 Menu Option 29 BASE L MENU Option Update Sensor Baselines Use the BASE L MENU option to update the zero concentration baselines for your electrochemical sensors Make sure the sampling probe is removed from the flue or disconnected from the instrument during zeroing If ESC is pressed before zeroing is complete previous baseline values are restored FUEL MENU Option Select Fuel Use the FUEL option to select from seven preset U S fuels or six Siegert fuels or select the USER fuel The fuels parameter list presented U S or Siegert is determined by the selection LOSS or gA respectively made from the UNITS MENU option Ci MENU FUEL Press the ENTER button to SD I initiate fuel selection U S 4 Fuels NATO 4 Press ENTER once PROP fuel is selected DIL2 4 OIL6 4 COAL 4 Press the ESC woud button to abort selection Use AV ARROW buttons to i select fuel Siegert 4 Press ENTER once Fu
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