DDS CAL2K-ECO User manual

HANDBOOK
HANDBOOK
VERSION NO.: 3.2
LAST UPDATED: 28 January 2016
Manufactured by:

E2K HANDBOOK V3.2 Website: www.cal2k.com i
Table of Contents:
1.!INTRODUCTION ...................................................................................................... 1!
1.1!HOW TO USE THIS MANUAL ................................................................................ 1!
1.2!HISTORY OF DDS BOMB CALORIMETERS .............................................................. 1!
2.!USER INFORMATION AND HELP AIDS ..................................................................... 3!
2.1!E2K HANDBOOK ................................................................................................ 3!
2.2!E2K OPERATING MANUAL ................................................................................... 3!
2.3!E2K MAINTENANCE MANUAL ............................................................................... 3!
2.4!CAL2K APPLICATION NOTES ............................................................................... 3!
3.!SYSTEM COMPONENTS ............................................................................................ 4!
3.1!THE E2K COMBUSTION CALORIMETER SYSTEM...................................................... 4!
3.2!THE E2K CALORIMETER ...................................................................................... 4!
3.3!THE E2K-2 COOLER ........................................................................................... 4!
3.4!THE E2K-FAN AIR COOLER.................................................................................. 5!
3.5!THE E2K-3 FILLING STATION .............................................................................. 5!
3.6!THE CAL2K-4 VESSEL......................................................................................... 5!
4.!INSTALLATION ....................................................................................................... 6!
4.1!UNPACKING AND INSPECTION ............................................................................ 6!
4.2!SETTING UP...................................................................................................... 6!
5.!SAFETY PRECAUTIONS ............................................................................................ 8!
5.1!CALORIMETER (CAL2K-E2K)................................................................................ 8!
5.2!COOLER (E2K-2) ............................................................................................... 8!
5.3!E2K AIR COOLER (E2K-FAN) – ONLY WITH THE MINIMUM SYSTEM........................... 8!
5.4!FILLING STATION (E2K-3) .................................................................................. 8!
5.5!VESSEL (CAL2K-4)............................................................................................. 9!
6.!CERTIFICATIONS ............................................................. Error! Bookmark not defined.!
7.!WARRANTY ...................................................................... Error! Bookmark not defined.!
7.1!WARRANTY – for NEW products ................................ Error! Bookmark not defined.!
7.2!WARRANTY – for RECONDITIONED AND REPAIRED products ..... Error! Bookmark not
defined.!
7.3!GENERAL – WARRANTY VOID ................................... Error! Bookmark not defined.!

E2K HANDBOOK V3.2 Website: www.cal2k.com 1
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 bomb calorimeter
systems available today. The system is used to measure the calorific value of both solids and liquids.
dds has three different Bomb Calorimeter models in their Scientific CAL2k range:
CAL2k
ECO
e2k
The CAL2k Calorimeter is
aimed at the higher volume
market; which requires higher
quantities of CV samples per
day.
A determination will take
approximately 7 minutes to
run and depending on the
number of Vessels used, 10
samples can be carried out
every hour.
The ECO Calorimeter is
inexpensive and aimed at the
lower volume market; which
requires very small quantities
of CV samples per day.
A determination will take
approximately 40 minutes to
run, and 1 (One) sample can
be carried out every hour.
The e2k Calorimeter is a
middle of the range product,
suited to both the lower and
higher volume markets. It
also comes with a fantastic
language compatible feature.
A determination can take
approximately 10 minutes
using the CAL2K-2 Cooler and
one Vessel.
You have chosen the CAL2K-ECO Bomb Calorimeter System, which is best suited for your calorimetry
requirements.
1.1 HOW TO USE THIS MANUAL
This Manual makes use of some informative symbols or icons, in order to bring your attention to the
text.
1.1.1 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.
1.1.2 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.
1.2 HISTORY OF DDS BOMB CALORIMETERS
In 1972, dds manufactured its first Calorimeter product the AMPC (Automatic Micro Processor
Calorimeter). It was a dual water isothermal unit controlled by a microprocessor. In 1980 a new
revolutionary design of Vessel, namely the DRY Vessel or CP510 was produced as it had no
surrounding water jacket. The determination time was significantly reduced, thus increasing the
product’s efficiency by 4 times.
With the processing power of the microprocessors available at the time, the CP500 Calorimeter was
born with its striking “buttercup yellow” colour. The CP500 proved to be a very fast and reliable
system and was exported to the USA, Europe, Scandinavia, Australasia, Africa and India.

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In early 2002 work began on the new CAL2k model. The tried and tested DRY system was retained
and only the very latest electronic technology was used, including surface mount devices. The CAL2k is
now in full production and is sure to be an even bigger success than its predecessor, the CP500. In
2005, dds realized the need for a smaller, low sample volume, and inexpensive calorimeter system
with the same accuracy and reliability of the CAL2k. Based on these requirements, the ECO was then
created as an alternative system to the CAL2k. By 2007, due to customer demands work began on the
e2k model. The e2k was designed to be able to have two language options – one being English and
the other an alternative language for example French. The e2k was also designed to work faster than
the ECO but not as fast as the CAL2k with less features as the CAL2k to keep it cost-effective.

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2. USER INFORMATION AND HELP AIDS
Included in your shipment is this printed Handbook as well as a CD. The CD includes Application
Notes, the Operating Manual, Maintenance Manual and the e2k Windows PC Software.
Below is a detailed description for each of the Help Aids provided:
2.1 E2K HANDBOOK
The Handbook is printed and included in your shipment. The Handbook contains useful information for
getting started, including:
•System components – what is included
•What each component is used for
•Unpacking instructions of the system
•Setting up the system
•Safety precautions
•Warranty details and registration
2.2 E2K OPERATING MANUAL
The Operating Manual is supplied on the CD. The manual contains information on the system
operation, including:
•Safety precautions
•Getting started
•System connections
•e2k firing voltages
•General operation
•Operating cycles
•Running a sample using the e2k demo kit
•Quick guide – quick reference guide to operating instructions
•Software Operating instructions
•Maintenance
•Hits and Tips
•Trouble shooting and solutions
•Technical specs
•Spare parts and installation kits
•etc.
2.3 E2K MAINTENANCE MANUAL
The Maintenance Manual is supplied on the CD. The Manual contain information on the maintenance
and service of your system:
•Self Testing
•Calorimeter maintenance
•Technical information of the Calorimeter
•Cooler maintenance (for Standard and Elite Systems)
•Filling Station maintenance
•Vessel maintenance
2.4 CAL2K APPLICATION NOTES
Application notes supplied on the CD are all the samples dds has tested using the CAL2k bomb
Calorimeter System. There are different types of applications namely: Fuel Oils, Ammunition, Coal,
Food & Nutrition, and Alternative Energy Sources.

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3. SYSTEM COMPONENTS
3.1 THE E2K COMBUSTION CALORIMETER SYSTEM
PLEASE NOTE: If you have purchased the Minimum System configuration, the CAL2K-2
Cooler will not be included with your order as it does not form part of that
configuration. If you have purchased the Standard or Elite System configurations the
CAL2K-2 Cooler is included with your order.
The full e2k Combustion Calorimeter System consists of the following items:
•Calorimeter (CAL2K-E2K)
•Cooler (E2K-2) Only supplied with Standard and Elite System configurations.
•Air Cooler (E2K-FAN) Only supplied with the Minimum System configuration.
•Filling Station (E2K-3)
•Vessels/Bombs (CAL2K-4)
This system has been specifically designed to ensure accuracy and reliability and is backed by a
technical team that are experts in their field.
3.2 THE E2K CALORIMETER
The Calorimeter is used to determine the energy content (calorific value) of a solid or liquid sample.
The sample is ignited inside the pressurised Vessel and then the
Calorimeter measures the temperature rise of the Vessel. This
temperature rise is proportional to the calorific value of the sample.
The Vessel’s chamber (Well) of the Calorimeter is insulated.
Width - 270mm
Height - 200mm
Depth - 380mm
Weight - 8kg
Power - 0 - 264VAC 50/60Hz 1W
3.3 THE E2K-2 COOLER
PLEASE NOTE: The Cooler is ONLY supplied with the Standard and Elite System
configurations.
Once the Vessel has been fired, it rises in temperature by approximately
9ºC for a 0.5g sample with a calorific value of approx. 27mJ/kg.
The Cooler is used to return the Vessel back to ambient temperature
within a few minutes.
Width - 280mm
Height - 250mm
Depth - 320mm
Weight - 10kg
Power - 85 – 264VAC 50/60Hz 150W

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3.4 THE E2K-FAN AIR COOLER
PLEASE NOTE: ONLY supplied as part of the Minimum System configuration.
The Air Cooler is used to cool a warm Vessel back to the approximate
ambient temperature in approx. 20 to 30 minutes.
Width - 130mm
Height - 180mm
Depth - 170mm
Weight - 2kg
Power - 220 Volts 50 Hz 0,1amps
Fuse - 100mA, Size 5 x 20mm.
3.5 THE E2K-3 FILLING STATION
The Filling Station is used to pressurise the Vessel with oxygen to 3MPa (3000Kpa).
This is required so that the sample will ignite and then burn away completely.
The oxygen rich environment allows quick and complete combustion of any solid
or liquid sample.
Width - 220mm
Height - 450mm
Depth - 300mm
Weight - 4.5Kg
3.6 THE CAL2K-4 VESSEL
The Vessel (traditionally called a Bomb) has a combustion chamber, which contains the burning
process and transfers the resulting heat into the Vessel’s walls, where it is measured. The Vessel has
temperature sensors built into the wall, so that the temperature rise can be measured and converted
to an energy value.
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 and a certificate
is issued for each Vessel , a copy of which is supplied with the Vessel.
Diameter - 82mm
Height - 150mm
Weight - 2.5Kg

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4. INSTALLATION
4.1 UNPACKING AND INSPECTION
By the time you read this Manual, you would have unpacked the e2k System. There are no special
precautions to be taken. The following check list is for your convenience:
1. Locate and tick-off the various system components as indicated on the Packing List provided.
2. Unpack and inspect all the system components such as the e2k Calorimeter, the E2K-2 Cooler
or e2k Air Cooler, the E2K-3 Filling Station, and the CAL2K-4 Vessel according to the
instructions in the relevant sections in this Manual.
3. Inspect everything for any physical damage during transit. If damaged, consult your Agent
immediately.
4. The Calorimeter has a GROUND (SAFETY EARTH) at the rear panel. This lug MUST be
connected to the EARTH supply to insure operating personal safety in case the power supply
fails.
5. Verify the earth connection of the mains outlet which you intend to use, by checking the
continuity to the nearest water pipe. Ask a qualified electrician to check it.
6. Connect the power supply unit and mains cable to the mains power supply on the
Calorimeter. Any power supply with 9V output, 100mA capacity, centre pin POS, can be used.
7. Observe that the Display on the Calorimeter comes ON. If not, check the mains connections
or consult your Agent immediately.
8. Connect mains to the E2K-2 Cooler (if purchased).
9. Run the system tests as explained in the Operational Manual. The Operating Manual is
supplied on CD.
4.2 SETTING UP
4.2.1 PREREQUISITES
Prior to installation of the e2k System, the User must provide the following:
1. A mains outlet for the e2k Calorimeter power supply.
2. A supply of oxygen at a pressure of 3.0-3.5Mpa (30-35 bars) (3000Kpa) within 2 - 10
meters of the e2k System. If bottled oxygen is used, a suitable high pressure oxygen regulator
must be supplied (See E2K-3 Filling Station).
3. If the E2K-2 Cooler has been purchased, a supply of water at normal tap pressure within 10
meters of the e2k System (See E2K-2 Cooler) needs to be supplied. A mains outlet is also
required.
4. If the e2k Air Cooler is supplied, only a mains outlet is required.
5. If a balance is supplied, ensure that a sturdy, stable weighing surface is available. A mains
outlet and a connecting cable are also required.

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4.2.2 SITE SELECTION
The e2k Calorimeter is a desktop unit, which can be installed wherever the laboratory space
permits, with two restrictions:
1. The measuring chamber (Well) of the e2k Calorimeter should not be exposed to very drastic
temperature changes. The Calorimeter’s chamber (Well) is double insulated to minimise the
effect, however, good installation helps. The inner measuring chamber of the Calorimeter is
measured and used as a reference by the E2K-2 Cooler. (If the Cooler has been ordered).
2. The e2k System, consisting of e2k Calorimeter, E2K-2 Cooler, (if supplied) 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.
Please see above for the dimensions, weights and power requirements per unit. The
BALANCE data would be dependent on the make and model. Approx. dimensions (in
mm): 250W x 450H x 500D.

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5. SAFETY PRECAUTIONS
5.1 CALORIMETER (CAL2K-E2K)
•Electrical Shock: There are no user serviceable parts inside.
•Do not open the back panel unless the mains cable has been disconnected.
•Dangerous voltages will be present inside the unit after the mains cable has been
disconnected.
•DO NOT TAMPER WITH THE EARTHING - CONSULT A QUALIFIED ELECTRICIAN SO
THAT THE EARTHING CAN BE CHECKED.
5.2 COOLER (E2K-2)
The Cooler is only supplied when the Standard and Elite System configurations have been purchased.
If you purchased a Minimum System configuration, you will receive an Air Cooler (E2K-FAN).
•Electrical shock: There are no user serviceable parts inside.
•Do not open with the water hoses connected.
•Disconnect from Mains before opening the Cooler (CAL2K-2).
•Dangerous voltages will be present inside the unit after the mains cable has been
disconnected.
•DO NOT TAMPER WITH THE EARTHING - CONSULT A QUALIFIED ELECTRICIAN SO
THAT THE EARTHING CAN BE CHECKED.
5.3 E2K AIR COOLER (E2K-FAN) – ONLY WITH THE MINIMUM SYSTEM
The Air Cooler is only supplied if the Minimum System has been purchased.
•If the fuse needs checking or replacing always disconnect the unit from mains before
removing the fuse cover.
•DO NOT TAMPER WITH THE EARTHING - CONSULT A QUALIFIED ELECTRICIAN SO
THAT THE EARTHING CAN BE CHECKED.
5.4 FILLING STATION (E2K-3)
•Secure the Filling Station to the table.
•Install the flexible high pressure pipe supplied without sharp bends.
•Check the nylon high pressure pipe supplied for any mechanical damage before putting it
under pressure.
•Secure the pipe nuts to the pressure regulator side, then clamp the ferrule to the high
pressure pipe on the gauge block side.
•If the oxygen bottle is not situated close to the Filling Station or if it is in another room or
even 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 E2K-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 E2K-3 Filling Station.
•The oxygen bottle should be secured according to regulations.
•DO NOT USE ANY OTHER PIPE OTHER THAN THE HIGH PRESSURE PIPE SUPPLIED.
•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.

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5.4.1 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.
•NEVER use oil or grease on any part of the gauge assembly or any part of the Filling
Station and Vessel for SAFETY reasons!
•DO NOT use a hammer to free a jammed valve.
•Use only the approved pressure reduction valve with a safety blow valve.
•Consult your safety engineer when in doubt.
5.5 VESSEL (CAL2K-4)
•The Vessel has been pressure tested (certificate will be provided if required), at 40 MPA
according to international standards.
•The Vessel and its Cap’s thread are subject to wear and tear, and must be inspected
regularly. Check for excessive play.
•A Vessel with “loose” or worn threads is dangerous, and it must be reconditioned by the
dds Factory.
•A Vessel with worn threads may cause the Cap to blow off during a determination, which is
extremely dangerous and may cause injury to the operator. Vessels with worn threads
which cannot be reconditioned will be deemed unsafe and a condemnation certificate will be
issued.
•Vessels should be returned to dds every 6 months for reconditioning, checking and
subsequent pressure tests. A Vessel will require reconditioning after 5000 firings; however
this quantity could be significantly reduced depending on the type of samples analysed.
Therefore it is advisable to have your Vessel(s) checked regularly. Vessels will need to be
returned to dds for reconditioning, an agent is not authorised to recondition a Vessel and
therefore it must be sent to dds for this procedure.
•Do not extend any part of your body over the e2k Calorimeter during the initial period.
•Consult your safety engineer or your mechanical engineer for guidelines, when in doubt.
•NEVER OPERATE ANY UNSAFE VESSEL.
•NEVER IMMERSE THE VESSEL INTO COLD WATER WHEN COOLING. USE THE
CAL2K-2 COOLER OR ALLOW THE VESSEL TO COOL DOWN NATURALLY.
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 CAL2K SYSTEM REGULARLY.

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6. CERTIFICATIONS

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7. WARRANTY
7.1 WARRANTY – FOR NEW PRODUCTS
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.
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.
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.
7.2 WARRANTY – FOR RECONDITIONED AND REPAIRED PRODUCTS
Any “dds” scientific product that has been repaired or reconditioned has a warranty period of 30 Days
from date of shipment for the Recon or Repair request only. If something else goes wrong that is
not part of the original Recon or Repair, the warranty does not apply. Each product that is sent to
“dds” for Reconditioning or Repair is tested and checked and leaves “dds’s” Factory in 100% working
order. It is the Owner’s responsibility to inspect any repaired or reconditioned 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/recon, the full cost of repair/recon will be applicable and paid for
by the Owner.

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7.3 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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WARRANTY REGISTRATION FORM
SERIAL NUMBERS (S/N): Calorimeter: _____________________________
Cooler/Air Cooler: _____________________________
Filling Station: _____________________________
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: __________________________________________________