AFRISO MAXILYZER NG Plus User manual

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für Haustechnik,
Industrie und Umweltschutz
Lindenstraße 20
74363 Güglingen
Telefon [phone]
Service [phone]
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[email protected]
www.afriso.de
 Read manual before use!
 Observe all safety information!
 Keep manual for future use!
04.2010 0
854.001.0541 Systronik-Artikel-Nr.: 23001
Instruction Manual
Flue gas analysis computer
MAXILYZER NG Plus

2 MAXILYZER NG Plus
Contents
1 About this instruction manual ..................................................................................4
1.1 Structure of warning .....................................................................................4
1.2 Explanation of symbols and typeface ..........................................................4
2 Safety.......................................................................................................................5
2.1 Intended use.................................................................................................5
2.2 Predictable incorrect application ..................................................................5
2.3 Safe handling ...............................................................................................5
2.4 Qualification of personnel.............................................................................6
2.5 Modifications to the product .........................................................................6
2.6 Use of spare parts and accessories.............................................................6
2.7 Liability information ......................................................................................6
3 Product description..................................................................................................7
3.1 Keyboard function ........................................................................................7
3.2 Status indicators...........................................................................................7
3.3 Display..........................................................................................................8
3.4 Measurement and calculation parameters...................................................9
3.5 Measuring procedure .................................................................................10
3.6 Peltier gas cooler .......................................................................................12
4 Specifications ........................................................................................................15
4.1 Calculation formulae (extract) ....................................................................20
4.2 Approvals, tests and conformities ..............................................................20
5 Transportation and storage ...................................................................................21
6 Commissioning ......................................................................................................21
6.1 Connecting scheme ...................................................................................22
6.2 Mounting and installation ...........................................................................23
6.3 Electrical connections ................................................................................23
6.4 Hose connections.......................................................................................23
7 Start menu .............................................................................................................24
8 Menu “Measure” ....................................................................................................25
8.1 Programme “Flue gas” ...............................................................................26
8.2 Programme “Temperature” ........................................................................44
8.3 Programme “Pressure”...............................................................................45
8.4 Programme “CO(O
2
) Measurement” ..........................................................46
8.5 Programme "Pitot Tube Measurement" (option) ........................................47
9 Menu “Macro Start”................................................................................................48
10 Menu “Time-Date” .................................................................................................49
11 Menu “Configuration”.............................................................................................51

MAXILYZER NG Plus 3
11.1 Change order of measured values on the display .....................................52
11.2 Configure list of fuels..................................................................................54
11.3 Change settings .........................................................................................58
11.4 Set default settings.....................................................................................62
12 Menu “Memory” .....................................................................................................63
13 Operation...............................................................................................................64
13.1 Notice concerning measurement of SO2 and NO2 (option) ......................64
13.2 Battery/line voltage operation (only for the measurement module) ...........64
13.3 Charging the batteries................................................................................65
14 Maintenance ..........................................................................................................67
15 Troubleshooting.....................................................................................................68
16 Shutting down and disposal...................................................................................69
17 Spare parts and accessories.................................................................................70
18 Warranty ................................................................................................................71
19 Copyright ...............................................................................................................71
20 Customer satisfaction ............................................................................................71
21 Addresses..............................................................................................................71
22 Appendix................................................................................................................72
22.1 Declaration of conformity ...........................................................................72

About this instruction manual
4 MAXILYZER NG Plus
1 About this instruction manual
This instruction manual is part of the product.


 Read this manual before using the product.


 Keep this manual during the entire service life of the product
and always have it readily available for reference.


 Always hand this manual over to future owners or users of the
product.
1.1 Structure of warning
WARNING TERM
The type and source of danger is shown here.


 Precautions to take in order to avoid the danger are shown
here.
There are three different levels of warning:
Warning term Meaning
DANGER Imminent danger!
Failure to observe the information will result in
death or serious injuries.
WARNING Possible imminent danger!
Failure to observe the information may result in
death or serious injuries.
CAUTION Dangerous situation!
Failure to observe the information may result in
minor or serious injuries as well as damage to
property.
1.2 Explanation of symbols and typeface
Symbol Meaning

Prerequisite for an activity



Activity consisting of a single step
1.
Activity consisting of several steps

Result of an activity
•
Bulleted list
Text Indication on a display
Highlighting Highlighting

Safety
MAXILYZER NG Plus 5
2 Safety
2.1 Intended use
The flue gas analysis computer MAXILYZER NG Plus is exclusively
suitable for the use in the following application areas:
• Professional settings and control-measurements at all smallfir-
ings-facilities (low temperature- and burner-value-boilers and -
thermal) for gas and oil applicable.
• With a second CO measuring cell (option) you can also use the
instrument for facilities for solid fuels as wood, coal etc.
• Measurements at bivalent and power modulatory communal
heating stations.
Any use other than the use explicitly stated in this instruction manual
is not permitted.
2.2 Predictable incorrect application
The flue gas analysis computer MAXILYZER NG Plus must never be
used in the following:
• Hazardous areas (ex)
If the device is operated in hazardous areas, sparks may cause
deflagrations, fires or explosions
• Use as a safety (alarm) unit or continuous measuring device.
2.3 Safe handling
This product represents state-of-the-art technology and is manufac-
tured in accordance with the pertinent safety regulations. Each unit is
subjected to a function and safety test prior to despatch.


 Operate the product only when it is in perfect condition. Always
observe the instruction manual, all pertinent local and national
directives and guidelines as well as health and safety regula-
tions and directives regarding the prevention of accidents.


 Perform an overall visual inspection of the measuring device
(including any accessories) prior to each operation of the MAX-
ILYZER NG Plus in order to ensure proper operation of the de-
vice.
Voltage supply


 Verify that the device is suitable for your mains. Make sure you
have the correct mains voltage when connecting the device.
This is a device of safety class 1, i.e. it has an earth connection. Any
interruption of the protective conductor inside or outside the device
or disconnecting the protective conductor connection may cause

Safety
6 MAXILYZER NG Plus
hazards. Intentional interruptions of the protective conductor are pro-
hibited.
The mains plug may only be plugged into an isolated earth power
outlet. Do not disable the protection effect by using an extension ca-
ble without a protective conductor.


 Disconnect the device from all voltage sources before trouble-
shooting or repairing it or before replacing parts.
WARNING Severe burns or death due to live parts.


 Do not touch parts under voltage with the instrument or sen-
sors.



If work must be performed on the device while it is connected to
voltage, such work may only be performed by a trained expert
who is familiar with the associated hazards!
2.4 Qualification of personnel
The product may only be installed, commissioned, operated, main-
tained, shut down and disposed of by qualified, specially trained per-
sonnel.
Electrical work may only be carried out by qualified electricians in
accordance with local and national regulations.
2.5 Modifications to the product
Changes or modifications made to the product by unauthorised per-
sons may lead to malfunctions and are prohibited for safety reasons.
2.6 Use of spare parts and accessories
Use of unsuitable spare parts and accessories may cause damage
to the product.


 Use only the manufacturer’s genuine spare parts and accesso-
ries (refer to chapter 17, page 70).
2.7 Liability information
The manufacturer shall not be liable for any direct or consequential
damage resulting from failure to observe the technical instructions,
guidelines and recommendations.
The manufacturer and the sales company shall not be liable for costs
or damages incurred by the user or by third parties in the use or ap-
plication of this device, particularly in case of improper use of the de-
vice, misuse or malfunction of the connection, malfunction of the de-
vice or of connected devices. The manufacturer or the sales com-

Product description
MAXILYZER NG Plus 7
pany shall not be liable for damages resulting from any use other
than the use explicitly stated in this instruction manual.
The manufacturer shall not be liable for misprints.
3 Product description
The MULTILYZER NG Plus flue gas analysis computer is a multiple -
function analyser with integrated calculating functions. Measure-
ments are in accordance with the general regulations set forth by the
German “BIMSchV” at all kinds of combustion plants within the
framework of the monitoring of exhaust systems.
The integrated Peltier gas cooler avoids accumulations of conden-
sate in the gas supply system and incorrect measurements of
strongly water-soluble gases such as NO2 and SO2.
3.1 Keyboard function
Key Function
Register/function key.
Backlight on/off.
Change register buttons line.
Switch to another row./Start macro or waste
gas measurement.
Gas pump on/off.
Close function or programme, cancel prece-
dure.
Enter.
Device on/off
3.2 Status indicators
Status indicator Function
Peltier gas cooler on/off.

Product description
8 MAXILYZER NG Plus
Status indicator Function
"TA±": Cooler control temperature.
"Active": Operating state Peltier element.
(See page 12 for detailed explanations)
"TA±": Operating state measured gas line.
"LA±": Condensate alarm sensor
(See page 12 for detailed explanations)
3.3 Display
1 Status line
2 Programme menu
3 Register key/menu line
Fig. 1: Display using the example of the start menu
Status line
This line continuously shows the status of certain information such
as remaining battery power, HOLD-function, sensor-alerts, operation
of the pump, chosen fuel, time etc. The priority of the information
shown thereby depends on the mode and function-specific criteria
respectively.
Programme menu
Programs can be selected or started in the programme selection
field.
Register key/menu line
The functions shown on the display can be selected with the register
keys. In some menus the keys F1, F2 and F3 have several functions

Product description
MAXILYZER NG Plus 9
that can be rotated by pressing the button in the centre of the key-
pad.
3.4 Measurement and calculation parameters
Table 1: Readings
Display Measured medium Unit
T.Gas Waste or flue gas temperature °C, °F
T.Room Air or ambient temperature °C, °F
O
2
Oxygen content % Vol.
CO Carbon monoxide content ppm, mg/m³,
mg/kWh, mg/MJ
CO
max
Maximum carbon monoxide con-
tent
ppm, % Vol.
Draft Draft/Pressure hPa, mbar, mmWs,
mmHg, inWc, inHg,
PSI
NO Nitrogen monoxide content (option)
ppm, mg/m³,
mg/kWh, mg/MJ
SO
2
Sulphur dioxide content (option) ppm, mg/m³,
mg/kWh, mg/MJ
NO
2
Nitrogen dioxide content (option) ppm, mg/m³,
mg/kWh, mg/MJ
CO+ Carbon monixide content, high
(option)
% Vol.
Table 2: Calculated values
Display Measured medium Unit
CO
2
Carbon dioxide % Vol.
CO
unv.
Carbon monoxide, undiluted ppm
Effi. Combustion efficiency %
Ex.air Excess air value
λ
qA Waste gas losses %
Dewpnt Fuel specific dew point °C, °F
T.Diff Differential temperature (TG-TA) °C, °F

Product description
10 MAXILYZER NG Plus
Display Measured medium Unit
NO
x
Nitride oxides (option) ppm, mg/m³,
mg/kWh, mg/MJ
NO unv. Nitrogen monoxide, undiluted (option) ppm
NO
x
unv.
Nitric oxides, undiluted (option) ppm
SO
2
unv.
Sulphur dioxide, undiluted (option) ppm
NO
2
unv.
Sulphur dioxide, undiluted (option) ppm
3.5 Measuring procedure
Table 3: Measuring procedure
Function Explanation
Temperature Measurement K-type thermocouple NiCr-Ni
O
2
- Measurement Electrochemical measuring cell
CO- Measurement Electrochemical measuring cell
NO- Measurement (Option) Electrochemical measuring cell
SO
2
- Measurement (Option) Electrochemical measuring cell
NO
2
- Measurement (Option) Electrochemical measuring cell
Pressure/Draft Measurement Piezo-resistive sensor with internal temperature
compensation
Measuring Duration Short-term memory measurements of max.
60 minutes are possible, followed by a new calibra-
tion phase with ambient air.
Waste Gas Measurement Via an external water separator and filter, the waste
gas is fed to the sensors by means of a gas feed
pump.
Sensor Calibration After having switched on the instrument there is a
calibration phase that takes 60 seconds after a cold
start. For repetition measurements it takes 10 sec-
onds (restart).

Product description
MAXILYZER NG Plus 11
Function Explanation
CO-Sensor Protection The standard equipped CO-Sensor with dynamic H
2
-
compensation is protected automatically by means of
a separate flushing pump when the upper boundary
of the measurement range is reached (> 4.000 ppm).
By doing so the sensor is supplied with sufficient
fresh air from the environment of the device. The
measurement starts again automatically as soon as
the value falls below 1.600 ppm. During the active
flushing phase the other readings aren’t influenced.
Waste Gas Sampling This is done by means of a suitable probe which
enables either a “One-Point-Measurement” (combi
probe) or a “Multi-Point-Measurement” (multi-hole
probe).

Product description
12 MAXILYZER NG Plus
3.6 Peltier gas cooler
The integrated Peltier gas cooler is designed for applications at
changing sites requiring high-precision gas analyses and involving
pollution and condensate in the flue gas.
The analysis of strongly water-soluble gases (NO2 and SO2) makes
the use of a Peltier gas cooler indispensable. The reduced dew point
of the measured gas avoids the formation of condensate and dirt
particles in the analyser and in other system components. At the
same time, a stable output dew point prevents vapour cross sensitiv-
ity and volumetric errors.
The gas cooler operates with an electronically controlled Peltier ele-
ment which ensures, together with the flow-optimised heat ex-
changer, an optimum dew point reduction to a value of approx. 5°C.
The condensate is discharged via a hose pump.
The Peltier cooler indicates the operating states of the individual sys-
tem components by means of status indicators.
Application example
Fig. 2: Application example Peltier cooler
The gas to be measured is drawn in via a gas sampling probe and a
heated gas line and supplied to the Peltier cooler. The heating hose
is heated to a temperature of 100 °C by a controller in the Peltier gas
cooler.
The gas cooler cools down the gas to a dew point of 5 °C; the con-
densate is discharged via a hose pump. The downstream fine filter
removes solid particles that may be contained in the gas.
Design
The Peltier gas cooler comprises a gas cooler with automatic con-
densate discharge as well as an easily accessible gas filter. An

Product description
MAXILYZER NG Plus 13
automatic pressure compensation valve ensures fast compensation
in the case of changing atmospheric pressures.
All controls, electrical connections as well as gas and condensate
connections are located on the front panel of the MAXILYZER NG
Plus. In addition, the device features status indicators whose function
is described in detail in subsequent chapters.
Gas sampling probe and heated gas line
Heating the gas from the sampling point all the way to the Peltier gas
cooler avoids accumulations of condensate in the gas supply system
and incorrect measurements of strongly water-soluble gases such as
NO2 and SO2. In addition, this function allows for gas sampling at
temperatures lower than 0 °C.
The integrated micro filter with a filter rating of 2 µm reliably removes
pollution with solid matter and can be easily replaced.
The electrically heated gas line with Pt100 temperature sensors is
available in two lengths (3 m or 5 m). MAXILYZER NG Plus controls
the temperature and indicates the status "TA±" of the heating hose.
The controlled temperature is 100 °C. If the reference temperature is
higher or lower by 10 K, the status LED lights red. The device is
ready for operation when the status LED switches from red to green.
The following functions are monitored and indicated.
Gas cooler
Gas cooler temperature "TA±" Reference value 5 °C, alarm at ±
3 °C
Function of Peltier element "Active" Control and function
System status
Heating hose temperature "TA±" Reference value 100 °C, alarm at ±
10 °C
Colour coding of the individual operating states:
• Status LED flashes or lights solid green: The corresponding sys-
tem component is ready for operation and works with the speci-
fied parameters.
• Status LED flashes or lights solid red: The corresponding sys-
tem component is either not yet ready for operation or the com-
ponent is defective.
• System status LED does not light up at all: The corresponding
function is of no relevance for the measurement.

Product description
14 MAXILYZER NG Plus
Status indicators "Gas Cooler"
• Status LED TA± lights green: The gas cooler is ready for opera-
tion. The controlled cooler temperature is within the temperature
tolerance range of 5 °C ± 3 °C.
• Status LED TA± lights solid red: The gas cooler is not ready for
operation. The controlled cooler temperature is outside the tem-
perature tolerance range of 5 °C ± 3 °C.
Possible reasons are:
• The gas cooler has been switched on and is still starting
up. The cooler should have reached the controlled tem-
perature after approx. 10 minutes.
• The cooling capacity is insufficient even though the Peltier
element operates in continuous mode. See status LED
"Active" for details.
• The Peltier element is defective. This is indicated by the
solid red Active LED.
• Status LED TA± flashes red: The temperature sensor of the gas
cooler is defective so that the temperature can no longer be
controlled. Contact the manufacturer or the service point in
charge in such a case.
The status LED "Active" monitors the function of the Peltier element
and provides information on the cooling capacity or degree of utilisa-
tion of the gas cooler.
• Status LED lights solid green: The Peltier element operates in
continuous mode. When the device starts up, this is a normal
condition. During measurement operation, continuous mode of
the Peltier element indicates that the maximum cooling capacity
has been reached due to a high input dew point or volume flow
or an excessively high ambient temperature.
• Status LED "Active" flashes green: The flashing frequency of
the status LED indicates the current state of the Peltier element
and thus provides information on the degree of utilisation of the
gas cooler.
• Status LED "Active" lights solid red: The Peltier element of the
cooler is defective. Contact the manufacturer or the service
point in charge in such a case.
Status indicators "System Status"
• Status LED TA± lights green: There are no drops of liquid in the
gas flow downstream the cooler. Correct measurements can be
made.

Specifications
MAXILYZER NG Plus 15
• Status LED TA± lights solid red: The condensate alarm sensor
LA+ has detected drops of liquid in the gas flow.
Possible reasons are:
• Cooling or discharge of the condensate do not work prop-
erly.
• Measurements are performed below the specified ambient
temperature of 10 °C so that there is condensation down-
stream the cooler.
• It was not possible to discharge a gush of water from the
sampling point via the condensate pump.
The status LED "TA±" indicates the current operating state of the
heated gas line.
• Status LED TA± lights solid green: The heating hose is ready
for operation. The controlled temperature is within the tempera-
ture tolerance range of 100 °C ± 10 °C.
• Status LED TA± lights solid red: The heating hose is not ready
for operation. The controlled temperature is outside the tem-
perature tolerance range of 100 °C ± 10 °C.
Possible reasons are:
• The device has been switched on and the heating hose is
still starting up. The heating hose should have reached the
controlled temperature after approx. 10 minutes.
• The heating element of the gas line is defective.
• Status LED TA± flashes red: The heating hose is not connected
or the Pt100 temperature sensor is defective.
4 Specifications
Table 4: Description of the device
Parameter Value
General
Dimensions 410 x 180 x 330 mm (W x H x D)
Weight Approx. 7000 to 7150 g (depends on
equipment with sensors)
Display Hi-res LCD-Module that can show graphi-
cal items. Either 5 or 10 readings plus
menu line can be displayed at a time.
Data communication USB-interface. Option: Bluetooth interface.
Printer Internal thermal printer

Specifications
16 MAXILYZER NG Plus
Parameter Value
Memory Max. 100 memory blocks including dy-
namic memory management and direc-
tory/file structure
Electrical supply NiMH-battery 6 V/4,5 Ah, external power
adapter and charger
Mains fuse T 10/250 V (4 x 20 mm)
Operating temperature range
Ambient +5 °C to +40 °C
Storage -20 °C to +50 °C
Table 5: Physical specifications
Parameter Wert
Waste or flue gas temperature measurement
Range -20 °C to +1000 °C
Accuracy ± 2 °C + 1 digit (-20 °C to 0 °C)
± 1 °C (0 °C to +200 °C)
± 0.5 % of reading (above +200 °C)
Resolution 1 °C
Sensor K-Type thermocouple NiCr-Ni
Combustion air temperature measurement
Range -20 °C to +1000 °C
Accuracy ± 2 °C + 1 Digit (-20 °C to 0 °C)
± 0.5 °C + 1 Digit (0 °C to +200 °C)
± 0.5 % of reading (above +200 °C)
Resolution 0.1 °C
Sensor K-Type thermocouple NiCr-Ni
Pressure measurement
Range ± 70 hPa (nominal)/± 130 hPa (maximum)
Accuracy ± 0.02 hPa + 1 digit (0 hPa to ±2.00 hPa)

Specifications
MAXILYZER NG Plus 17
Parameter Wert
Resolution ±1% of reading (±2.01 hPa to ±70.0 hPa)
±2% of reading (±70.1 hPa to ±130.0 hPa)
0.01 hPa (to 20.99 hPa); 0.1 hPa (above 21.0 hPa)
Sensor Semiconductor sensor
Oxygen (O
2
) measurement
Range 0-21.0 % Vol.
Accuracy ± 0.2 % Vol. of reading
Resolution 0.1 % Vol.
Sensor Electro-chemical cell
Response
time (T90)
50 seconds
Carbon dioxide (CO
2
) calculation
Range 0 to CO
2 max
(fuel-specific)
Accuracy ± 0.2 % Vol. of reading
Resolution 0.1 % Vol.
Sensor Calculated from O2 measurement
Response
time (T90)
50 seconds
Carbon monoxide (CO) measurement (with H
2
compensation)
Range 0-4000 ppm
Accuracy 3 ppm (up to 20 ppm)
5 % of reading (above 20 ppm)
Resolution 1 ppm
Sensor Electro-chemical cell
Response
time (T90)
60 seconds

Specifications
18 MAXILYZER NG Plus
Table 6: Physical specifications – options
Parameter Value
Nitrogen monoxide (NO) measurement
Range 0-5000 ppm
Accuracy 5 ppm (up to 50 ppm)
5 % of reading
Resolution 1 ppm
Sensor Electro-chemical cell
Response time (T90) 60 seconds
COhigh measurement (without H
2
compensation)
Range 0-4.0 % Vol. (40,000 ppm)
Accuracy 5 % of reading (± 1 digit)
Resolution 0.01 % Vol.
Sensor Electro-chemical cell
Response time (T90) 60 seconds
SO
2
-measurement
Range 0-5000 ppm
Accuracy 10 ppm (up to 200 ppm)
5 % of reading (up to 200 ppm)
Resolution 1 ppm
Sensor Electro-chemical cell
Response time (T90) 150 seconds
NO
2
-measurement
Range 0-200 ppm
Accuracy 10 ppm (up to 50 ppm)
10 % of reading (up to 50 ppm)
Resolution 1 ppm
Sensor Electro-chemical cell
Response time (T90) 180 seconds

Specifications
MAXILYZER NG Plus 19
Table 7: Physical specifications Peltier gas cooler
Parameter Value
Measurement conditions
Input dew point Max. 60°C
Gas pressure (input) -100 mbar < p < +250mbar
Dust admission < 200g/m³
Design
Protection (closed) IP 65
Protection (open/during
operation)
IP 20
Electrical connections
Voltage supply AC 230 V/low temperature connector
Heating hose/sampling
probe
AC 230 V/round connector CA6
Power input Peltier cooler
50 W
Power input heating hose Max. 600 W
Fuse 10 A slow-blow (4 x 20 mm)
Electr. device standard EN 60204-1 (DIN VDE 0113-1/02.86)
Peltier gas cooler
Cooler type Peltier cyclone cooler
Output dew point 5 °C (factory-adjusted)
Dead volume (total) Approx. 50 ml
Wetted parts PA, PTFE, Viton
Ready to operate < 15 minutes
Condensate pump Hose pump
Heating hose
Sensor type Temperature sensor Pt100
Heating hose temperature
100 °C (factory-adjusted)
Electrical data AC 230 V/max. 600 Watt
Electrical connection 7 pin round connector type: CA6xxx
Heating hose length 3 m or 5 m (option)

Specifications
20 MAXILYZER NG Plus
Parameter Value
Sampling probe
(Standard) type V2A 1.4571 (300 mm)
4.1 Calculation formulae (extract)
Calculation of the CO
2
value
CO
2
= CO
2 max
* (1 -
21
O 2
) in %
CO
2max
Max. CO
2
value (fuel-specific) in % Volume
O
2
Measured oxygen content in % Volume
21 Measured oxygen content in % Volume
Calculation of the waste gas loss
qA = (T.Gas - T.Air) * (
2
2
O21
A
−
+ B) in %
T.Gas Waste/flue gas temperature in °F or °C
T.Air Combustion/ambient temperature in °F or °C
A2, B Fuel-specific factors
Calculation of the excess air value Lambda
Lambda =
2
max2
CO
CO
=
2
O21
21
−
Calculation of the combustion efficiency value (Eta)
Eta = 100 - qA in %
Calculation of CO 0% (undiluted)
CO
unv.
= CO * Lambda
CO
unv.
Content of carbon monoxide, undiluted
CO Reading for CO
4.2 Approvals, tests and conformities
Maxilyzer NG Plus is approved as per 1
st
German Federal Immission
Act (Bundesimmissionsschutzverordnung) and EN 50379-2. It is
TÜV-tested and complies with the applicable directives 2004/108/EC
(EMC) and 2006/95/EC (low voltage).