DDS Calorimeters CAL3K-F User manual

3K-F
INSTALLATION GUIDE
VERSION NO: 6
DATE: 2023
MANUFACTURED BY:

CAL3K-F INSTALLATION GUIDE V6 Website: www.ddscalorimeters.com i
Digital Data Systems (Pty) Ltd.
CAL3K Advanced Bomb Calorimeters
www.ddscalorimeters.com
Table of Contents:
1!INTRODUCTION .................................................................................................................... 1!
1.1!PURPOSE OF THIS MANUAL .......................................................................... 1!
1.2!HOW TO USE THIS MANUAL.......................................................................... 1!
1.2.1!WARNING SYMBOL................................................................................ 1!
1.2.2!INFORMATION (NOTE) SYMBOL .............................................................. 1!
2!USER INFORMATION AND HELP AIDS ................................................................................... 1!
3!SYSTEM COMPONENTS ......................................................................................................... 2!
3.1!THE CAL3K-F SYSTEM CHECK LIST ................................................................ 2!
3.2!THE 3K-F CALORIMETER WITH EXTERNAL OXYGEN FILLING .............................. 3!
3.3!THE 3K-2 AIR COOLER ................................................................................. 3!
3.4!THE 4K-4 THREAD VESSEL ........................................................................... 4!
3.5!THE 3K-3 OXYGEN FILLING STATION ............................................................. 4!
4!INSTALLATION ...................................................................................................................... 5!
4.1!UNPACKING AND INSPECTION ...................................................................... 5!
4.2!SETTING UP................................................................................................ 6!
4.2.1!PREREQUISITES ................................................................................... 6!
4.2.2!SITE SELECTION................................................................................... 6!
4.2.3!ASSEMBLING THE CAL3K-F .................................................................... 7!
5!TESTING ............................................................................................................................... 9!
5.1!TEST CAL3K HARDWARE .............................................................................. 9!
5.2!TEST VESSEL HARDWARE............................................................................. 9!
6!SAFETY PRECAUTIONS .......................................................................................................... 9!
6.1!CALORIMETER (3K-F)................................................................................... 9!
6.2!FILLING STATION (3K-3).............................................................................. 9!
6.2.1!HIGH PRESSURE OXYGEN .....................................................................10!
6.3!COOLER (3K-2) ..........................................................................................10!
6.4!VESSEL (4K-4)...........................................................................................11!
7!DAILY SAFETY STEPS ........................................................................................................... 12!
8!WARRANTY – FOR NEW PRODUCTS .................................................................................... 13!
8.1!PURPOSE OF PRODUCT WARRANTY...............................................................13!
8.2!OWNER’S WARRANTY..................................................................................13!
8.3!EXCLUDED (NON-WARRANTY) PARTS ............................................................13!
8.4!WARRANTY – REPAIRED PRODUCTS..............................................................14!
8.5!GENERAL – WARRANTY VOID .......................................................................14!
8.6!WARRANTY REGISTRATION FORM.................................................................15!

CAL3K-F Installation Guide V5 2022 Website: www.ddscalorimeters.com 1
Digital Data Systems (Pty) Ltd.
CAL3K Advanced Bomb Calorimeters
www.ddscalorimeters.com
1 INTRODUCTION
Digital Data Systems (Pty) Ltd (dds) specializes in the design and manufacture of scientific bomb
calorimeter systems for various types of industries and applications from the coal mining industry to
educational institutes. dds bomb calorimeter systems are the most advanced combustion calorimeter
systems available today. The system is used to measure the calorific value of both solids and liquids. dds
has a wide range of systems to suit different applications and sample requirements. Please visit our
website: www.ddscalorimeters.com to find out more. You have chosen the CAL3K-F Bomb Combustion
Calorimeter System, which is best suited for fast and accurate calorimetry operations.
1.1 PURPOSE OF THIS MANUAL
It serves as a short introduction to the CAL3K-F system and the various components. It explains the very
basics of operation and guides you to perform hardware tests and do the first determination. It relies on
the DEFAULT setting and the factory calibration.
But there is more: Information and capability! This is not explained here but in an ON-LINE version. It is
safe to say that you need a PC or laptop to change from the basic operation to a more sophisticated or
suitable one.
1.2 HOW TO USE THIS MANUAL
This Manual makes use of some informative symbols or icons, to bring your attention to the text.
1.2.1 WARNING SYMBOL
This yellow triangle with an exclamation mark inside it indicates a WARNING message or a
message that is instructing you NOT to do something. Please take note of this message, because
if you ignore it you could damage the Calorimeter equipment.
1.2.2 INFORMATION (NOTE) SYMBOL
This white hand with a finger pointing indicates a NOTE or INFORMATIVE message. It indicates
something that you need to pay attention to. Please take note of this message, as it provides
special or detailed information about a particular item.
2 USER INFORMATION AND HELP AIDS
Included in your shipment is this printed Installation Guide.
The on-line Help Guide for basic system operations, trouble-shooting and solutions, application notes as
well as how everything functions is available on-line and can be found at www.ddscalorimeters.com .
Please note the CAL3K-F Windows Software can be downloaded from the following link:
https://ddscalorimeters.com/dds-software/cal3k/

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3 SYSTEM COMPONENTS
3.1 THE CAL3K-F SYSTEM CHECK LIST
The system consists of the following:
3K-F
CAL3K-F Calorimeter
1
Received
3K-MAN-KT
CAL3K-F Calorimeter Installation Kit
1
Included in Kit:
3K-1-055
3K External 12V/1.5A Power Supply
1
3K-1-117
Balance Cable
1
3K-1-084
PC Cable (USB)
1
3K-1-061
PC Keyboard (PS2)
1
3K-4-049
Preparation Stand
1
3K-1-081
Stainless Steel Tweezers
1
3K-4-084
Certified Benzoic Acid Tablets (150 x 0.5g Tablets per Bottle)
1
3K-4-106
Wire Brush
1
3K-1-043
USB Memory Flash Drive with software, manuals etc.
1
3K-3-18
Emergency Deflate Cap
1
INSTALLATION-MANUAL
CAL3K-F Installation Guide Printed
1
3K-2
CAL3K Air Cooler
1
3K-2-KT
CAL3K Air Cooler Installation Kit
1
Included in Kit:
3K-1-055
3K External 12V/1.5A Power Supply
1
3K-3
CAL3K Filling Station
1
3K-3-KT
CAL3K Filling Station Installation Kit
1
Included in Kit:
3K-3-29
Nozzle O-rings used in de-filler cap & filling station
5
3K-3-21
Oxygen Regulator Connection - Quick Fit
1
3K-3-27
High Pressure Oxygen Pipe 4mm (3.75m) (Clear)
3.75M
3K-3-22
De-filler Cap
1
3K-1-080
Nozzle O-rings used in filling station
2
3K-3-32
Allen Key
1
3K-1-086
O-Ring Lubrication Grease tube
1
4K-4
CAL3K-F Thread Vessel
2
3K-4-KT
CAL3K-F Thread Vessel Installation Kit
2
Included in Kit:
3K-4-096
Centre Electrode Complete
2
3K-4-037
Outside Electrode M3
2
3K-4-047
Crucibles
2
3K-4-092
Deflector Plate
2
3K-4-093
Firing Wire (1 packet of 5)
1
3K-4-065
Firing Cotton Packet (1 packet of 100)
2
3K-4-094
Lid O-Rings
5
3K-4-022
Top & Bottom O-ring
10

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Digital Data Systems (Pty) Ltd.
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3.2 THE 3K-F CALORIMETER WITH EXTERNAL OXYGEN
FILLING
The CAL3K-F uses the Dynamic method (Isothermal) of
determination while still using the DRY method. The
prepared vessel is filled with oxygen in the external filling
station and placed in the calorimeter and the lid is closed.
The rest is automatic!
Width - 270mm
Height - 200mm
Depth - 380mm
Weight - 8kg
Power - 220-240V / 12W
3.3 THE 3K-2 AIR COOLER
The air cooler requires no water, piping, or other resources. The Air
Cooler is supplied with an external 12V power supply and a suitable
mains cable.
The air cooler will cool the vessel in approximately 6-8 minutes to the
specified setting. The operation of the cooler can be set via the USB
port and the CAL3K-F application software or from the CAL3K-F The
cooler is factory configured before shipment.
Width - 155mm
Height - 235mm
Depth - 285mm
Weight - 3 to 4kg
Power - 12VDC

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3.4 THE 4K-4 THREAD VESSEL
The ignition and burning process is contained within a chamber so
that the energy released can be measured in the form of heat. The
Vessel has temperature sensors built into it, so that the temperature
rise can be measured.
Because of the high pressure of oxygen required for combustion, the
Vessel is classified as a “Pressure Vessel” and is consequently tested
by an inspection authority to 10 times its normal pressure.
Diameter - 63mm
Height - 150mm
Weight - 2kg
3.5 THE 3K-3 OXYGEN FILLING STATION
The oxygen filling station is connected to the oxygen bottle via a
regulator. The regulator reduces the bottle pressure to 30bar, which
is adjustable. The regulated pressure is then supplied to the filling
station, which shows the supply pressure. Once a vessel is placed in
the filling station and the lever is lowered the vessel pressure is
indicated and the actual filling progress can be observed. The filling
speed is adjustable to suit the sample material.
Width - 220mm
Height - 450mm
Depth - 300mm
Weight - 4.5Kg

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4 INSTALLATION
4.1 UNPACKING AND INSPECTION
There are no special precautions to be taken when unpacking your system. The following check list is for
your convenience:
1. Locate and tick-off the various system components as indicated on the CAL3K-F Check List as per
above.
2. Unpack and inspect all the system components such as the 3K-F Calorimeter, 3K-2 Air Cooler,
3K-3 Filling Station and the 4K-4 THREAD Vessels according to the instructions in the relevant
sections in this document.
3. Inspect everything for any physical damage during transit. If damaged, consult your Agent
immediately.
4. The Calorimeter has a GROUND (SAFETY EARTH) lug at the rear panel. This lug MUST be
connected to the EARTH supply to ensure operating personal safety in case the power supply
fails.
5. Verify the earth connection of the mains outlet, which you intend to use. Ask a qualified
electrician to check it.
6. Connect the power supply to the mains power and to the Calorimeter. Any power supply with
12V output, 3000mA capacity, centre pin POS, can be used.
7. Do the same for the COOLER.
8. Observe that the Display on the Calorimeter comes ON. If not, check the mains connections or
consult your Agent immediately.
9. Observe that the Display on the COOLER comes ON. If not, check the mains connection or
contact your agent.

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4.2 SETTING UP
4.2.1 PREREQUISITES
Prior to installation of the CAL3K-F System, the User must provide the following:
1. A mains outlet for the 3K-F Calorimeter and a mains outlet for the 3K-2 Air Cooler power supplies.
2. A supply of oxygen at a pressure of 3.0Mpa (30bars) (3000Kpa) within 4 meters of the 3K-F
Calorimeter. If bottled oxygen is used, a suitable high-pressure oxygen regulator must be
supplied. Digital Data Systems can supply a single stage high-pressure oxygen regulator; contact
your agent for more information.
3. If a balance is supplied, ensure that a sturdy, stable weighing surface is available. A mains outlet
and Balance connecting cable will also be required (balance cable supplied as part of kit).
4.2.2 SITE SELECTION
The 3K-F Calorimeter is a desktop unit, which can be installed wherever the laboratory space permits,
with two restrictions:
1. The CAL3K-F system, consisting of 3K-F Calorimeter, 3K-2 Air Cooler, should be connected to a
mains circuit without heavy inductive or SCR switched equipment. It is safe to have balances or
other small electronic apparatuses on the same circuit. Good installation practice would be to
have a separate fused mains circuit with separate earth leakage supply (or an earth current
monitor, if applicable) for every system component. Future computers and peripherals installed
can be connected to the same circuit.
2. The unit should be in a place with a stable temperature, not in direct sun light or in the outlet
path of an air conditioner.
Please see above for the dimensions, weights, and power requirements per unit. The BALANCE
data would be dependent on the make and model that you will be using.

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4.2.3 ASSEMBLING THE CAL3K-F
The unit is shipped with a set of spares and some items required for operation. The operational items
need to be assembled before the unit is operational. The reason we ship the lid unlatched is due to
customs purposes. If customs officials wish to inspect inside the CAL3k-F calorimeter the lid is locked
therefore we must ship with the lid and latches loose so that customs can inspect.
The following requires assembling on the CAL3k-F:
1. The Lid locking mechanism on the calorimeter will need to be fitted. Locate the Lid locking
‘loop’ and the two screws and screw the loop into the lid. The loop was removed to enable
customs inspection. Do not close the lid! It opens only with power.

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2. The Lid stop will also need to be fitted to the back panel of the calorimeter.
a. First unscrew the back panel as shown in the picture below.
b. Fit the Lid Stop onto the back panel as shown in the picture below using the screws
supplied.
c. Fit the back panel back as indicated in the picture below.

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5 TESTING
It is recommend to run a calorimeter hardware test and a vessel hard ware test after installation
and before operation of the system.
5.1 TEST CAL3K HARDWARE
The test is activated by F9 or by:
13 CAL3K-TEST: 0
This command tests the CAL3K hardware. Once started the unit will cycle through all tests and will
‘hang’ on any fault. Individual test can be executed (without cycling through all preceding test) by
replacing the ‘YES’ entry by the test number.
This test should be repeated once a day. The vessel must not be in the well.
5.2 TEST VESSEL HARDWARE
This test is activated by F7 or:
14 VESSEL-TEST: 0
The vessel must be in the well.
6 SAFETY PRECAUTIONS
6.1 CALORIMETER (3K-F)
• Connect the safety earth to the EARTH STUD on the back of the instrument. This is required
when the external power supply fails
• Do not open the CAL3K for any reason whatsoever! There are no serviceable parts inside the
unit.
DO NOT TAMPER WITH THE EARTHING - CONSULT A QUALIFIED ELECTRICIAN SO THAT THE
EARTHING CAN BE CHECKED.
6.2 FILLING STATION (3K-3)
• Install the flexible high-pressure pipe supplied without any sharp bends.
• Check the nylon high-pressure pipe supplied for any mechanical damage before putting it under
pressure.
• Secure the pipe into the quick connector and screw the connector to the pressure regulator side.
Secure the pipe nuts to the pressure regulator side, then clamp the ferrule to the high pressure
pipe on the gauge block side.

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• If the oxygen bottle is not situated close to the Filling Station or if it is in another room or perhaps
outside, then a solid, permanent installation of pressure piping should be installed, as well as a
shut off valve and pressure gauge within easy reach of the 3K-3 Filling Station.
• If bottled oxygen is used, a suitable High Pressure oxygen regulator must be supplied by your
Agent, or sourced locally. Ordering this item from the factory ensures that the necessary
modifications have been made to fit the 3K-3 Filling Station.
• The oxygen bottle should be secured according to regulations.
• Secure the pipe to the side of the filling through the supplied device
• Do not use any oil or grease on any of the oxygen fittings or the O-rings. A very small amount of
high-pressure (vacuum) grease is allowed on the O-ring to make them pliable. Wipe them clean
afterwards.
• DO NOT USE ANY OTHER PIPE OTHER THAN THE HIGH PRESSURE PIPE SUPPLIED FOR OXYGEN
FILLING.
• DO NOT USE THE HIGH PRESSURE PIPE IF IT HAS A SHARP BEND OR KINK, DISCARD
IMMEDIATELY
• ALWAYS FILL THE VESSEL WITH OXYGEN TO A MAXIMUM PRESSURE OF 3000KPA (30
bar).
• NOTE: With some applications you may need to fill the Vessel to less than 3000KPA e.g. 1500KPA
(15 bar), however this is only applicable when you have a sample which is highly combustible, for
example with wood related samples.
• REMEMBER: You may fill the Vessel LESS than 3000KPA but NEVER more than 3000KPA.
6.2.1 HIGH PRESSURE OXYGEN
• The type of Oxygen to be used is the standard Industrial Oxygen used for welding. A purity of
99.5% will be suitable.
• Conform to the industry standard of handling procedures for oxygen bottles.
• Secure the bottle against a wall.
• Should the Oxygen supply be in another room, make sure there is a high pressure shut off
valve near the 3K-3 Filling Station installation.
6.3 COOLER (3K-2)
• There are no user serviceable parts inside.

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6.4 VESSEL (4K-4)
• Handle the vessel over a table or solid surface.
• Do not drop a vessel.
• Do not overfill a vessel with oxygen: The maximum oxygen filling pressure is 30bar / 3000kPA, which
is the standard for bomb calorimetry.
• Do not use any tools to open or close the vessel. If the vessel fails to deflate use the pre-scribed
‘emergency deflate’ procedure as outlined in the CAL3K-F Operations Manual, which uses the 3K-3-18
EMERGENCY DEFLATE tool (3K-3-18).
• Use the provided De-filler cap only, part number: 3K-3-22.
• Do not use any oil or grease on any of the oxygen fittings or the O-rings. A very small amount of high-
pressure (vacuum) grease is allowed on the O-ring to make them pliable. Wipe them clean afterwards.
• Store the vessel with the lid open. Never store a vessel under pressure, always deflate using the de-
filler cap.
• Clean the inside of the vessel with paper towel after every use.
• Weigh the crucible every week and discard it when it has lost 10% of its original mass.
• Discard the crucible when the bottom is distorted and extremely discoloured.
• Remove the deflector plate every week and clean the top surface. It does accumulate residue and
must be clean regularly.
• Make sure to use the pipe-clamping device on the right side of the filing station for safe use.
• NEVER OPERATE ANY UNSAFE VESSEL.
• NEVER IMMERSE THE VESSEL INTO COLD WATER WHEN COOLING. USE THE 3K-2 AIR
COOLER OR ALLOW THE VESSEL TO COOL DOWN NATURALLY.
• A SUITABLE INSPECTION WARNING PERIOD OF 2000 FIRINGS, AND A STOP OPERATING LIMIT OF
2500 FIRINGS ARE PRE-PROGRAMMED FROM THE FACTORY
THE VESSEL MUST BE INSPECTED AT REGULAR INTERVALS DEPENDING ON THE USE. A SUITABLE
INSPECTION PERIOD CAN BE SET (By your agent!) AND THE UNIT WILL ISSUE AN INSPECTION
WARNING AND SOON AFTER THIS IT WILL SHUT-DOWN THE OPERATION.
NOTE: THE MANUFACTURER (DDS) AND ITS AGENTS CANNOT BE HELD RESPONSIBLE FOR ANY
LOSS OR DAMAGE RESULTING FROM NEGLIGENCE OR INCORRECT USE OF THEIR EQUIPMENT.
IT IS YOUR DUTY AND RESPONSIBILITY TO CHECK ALL SAFETY ASPECTS OF THE CAL3K-F
SYSTEM REGULARLY.

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7 DAILY SAFETY STEPS
The 4K-4 vessel is a high-pressure apparatus and should be treated with care.
• Handle the vessel over a table or solid surface.
• Do not drop a vessel.
• Do not overfill a vessel with oxygen: The maximum oxygen filling pressure is 30bar / 3000kPA, which
is the standard for bomb calorimetry.
• Do not use any tools to open or close the vessel. If the vessel fails to deflate use the pre-scribed
‘emergency deflate’ procedure as outlined in the CAL3K-F Operations Manual.
• Use the provided De-filler cap only, part number: 3K-3-22.
• Do not use any oil or grease on any of the oxygen fittings or the O-rings. A very small amount of high-
pressure (vacuum) grease is allowed on the O-ring to make them pliable. Wipe them clean afterwards.
• Store the vessel with the lid open. Never store a vessel under pressure, always deflate using the de-
filler cap.
• Clean the inside of the vessel with paper towel after every use.
• Weigh the crucible every week and discard it when it has lost 10% of its original mass.
• Discard the crucible when the bottom is distorted and extremely discoloured.
• Remove the deflector plate every week and clean the top surface. It does accumulate residue and
must be clean regularly.
• Make sure to use the pipe-clamping device on the right side of the filing station for safe use.
WATCH YOUTUBE VIDEO ON CAL3K-F
UNPACKING AND INSTALLATION!

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8 WARRANTY – FOR NEW PRODUCTS
8.1 PURPOSE OF PRODUCT WARRANTY
Any part of a product is subject to ageing and eventual failure. These failures occur during normal use.
The purpose of a warranty is to protect the Owner against a part failure caused by manufacturing defects
in workmanship, material or design for a specific time.
8.2 OWNER’S WARRANTY
In the event of the Owner contracting directly with Digital Data Systems (Pty) Ltd “dds”, or in the event of
the installation of a unit arising out of a contract between the Owner’s Dealer or any other party on his/her
behalf and the said “dds”, the Owner records that not withstanding same, this warranty is the only
warranty applicable to “dds” units and is expressly in lieu of all other warranties, expressed or implied,
including any implied warranty of merchantability or fitness for a particular purpose. No amendments or
additions to this warranty shall be binding on “dds”, unless recorded in writing and signed by a duly
authorised officer of the company. “dds” agrees to repair and replace with a new or remanufactured
part, any part, other than those excluded below, which after inspection, upon its return to the factory
in Randburg, Johannesburg by the Owner or the authorised Dealer to which he/she returns the unit, is
proven to be defective.
Replacement of a defective part will be made only within the applicable warranty period of 12 (twelve)
months from date of shipment. Not withstanding anything to the contrary herein, any labour involved in
repairing or replacing a defective part will be charged at “dds” rates applicable at the time.
If upon inspection it is found that the pressure vessel was submerged in water the warranty
will automatically be null and void and the owner will be responsible for the labour and
parts charges.
8.3 EXCLUDED (NON-WARRANTY) PARTS
“dds” shall be entitled to treat this warranty as void unless the relevant warranty form (attached) is sent
by registered post to “dds” by the Owner within 10 (ten) days from date of original installation.
Regardless of warranty-status, the Owner shall be responsible for labour charges connected with periodic
maintenance requirements involving visual and functional inspection of the systems.
This warranty expressly covers the unit(s) “dds” supplied only and does not cover any other part, which
may, as a consequence of the installation and operation of the unit, become damaged in any way
whatsoever.
Special attention should be given to the safe operation of the high-pressure Vessels. The published rules
are guidelines only and enclosed in this leaflet for the convenience of the User. The manufacturer is not
responsible for any damages, consequential, indirect or direct, or loss whatsoever, resulting out of
electrical shock, Vessel explosion, or any other cause.

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8.4 WARRANTY – REPAIRED PRODUCTS
Any “dds” scientific product that has been repaired has a warranty period of 30 Days from date of
shipment for the Repair request only. If something else goes wrong that is not part of the original Repair,
the warranty does not apply. Each product that is sent to “dds” for Repair is tested and checked and leaves
“dds’s” Factory in 100% working order. It is the Owner’s responsibility to inspect any repaired product on
receipt thereof and confirm in writing, any faults, errors or problems with the said product. If a fault,
error or problem is reported after the 30 Day warranty period, and “dds” finds that the product has been
damaged and requires another repair, the full cost of repair will be applicable and paid for by the Owner.
8.5 GENERAL – WARRANTY VOID
All serial numbers on any relevant “dds” Scientific product need to remain on the product at all times, or
warranty will be void. Warranty will also be void if any of the branding stickers or decals have been
removed and/or the colour of the Scientific product has been changed in any way.

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8.6 WARRANTY REGISTRATION FORM
SERIAL NUMBERS (S/N): Calorimeter: _____________________________
Air Cooler: _____________________________
Vessel(s): _____________________________
Other: _____________________________
DEALER NAME: _____________________________________________________________
OWNER’S/CUSTOMER’S COMPANY NAME: _______________________________________
AUTHORISED BY: _____________________________________________________________
INSTALLED AT: _____________________________________________________________
TEL NO: ____________________________ FAX NO: ______________________________
CONTACT PERSON: ________________________________________________________
INSTALLED BY: _____________________________________________________________
DATE INSTALLED: ____________________________ (REPRESENTATIVE OF DEALER/AGENT)
CUSTOMER ORDER NUMBER AND DATE: _______________________________________
INSTALLATION DETAILS (LOCATION, WATER SUPPLY, AIR-CONDITIONING ETC.):
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
ACCEPTED IN GOOD CONDITION:
DATE: ______________________ SIGNATURE: ____________________________
NAME (printed): ____________________________
WITNESS: ____________________________
I have read, understood and accepted the conditions of this warranty, the details of which are printed in this Manual.
CUSTOMER’S SIGNATURE: __________________________________________________
NAME (printed): __________________________________________________
DATE: ___________________________________________