Dräger FG7000 User manual

5695061
Edition 01 – April 2016
en
Operating Instructions Dräger FG7000
Dräger MSI GmbH
Rohrstraße 32
58093 Hagen
Tel.: [phone]
Fax: [phone]
Email: [email protected]

Operating Instructions Dräger FG7000
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Edition 01 – April 2016
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Contents
1. Information.......................................................................................................................3
1.1 Warning signs.............................................................................................................3
1.2 For your safety............................................................................................................3
1.3 Safety instructions and warnings ................................................................................4
1.4 Bluetooth.....................................................................................................................4
1.5 Disclaimer...................................................................................................................5
1.6 Maintenance and servicing .........................................................................................5
1.7 Disposal......................................................................................................................5
2. Application.......................................................................................................................6
3. The product......................................................................................................................7
3.1 The measuring device.................................................................................................7
3.2 The flue gas probe......................................................................................................8
3.3 The multi-hole adapter................................................................................................8
3.4 The annular adapter....................................................................................................8
4. First time use and operation ............................................................................................9
4.1 Preparation for first time use.......................................................................................9
4.1.2 Prior to each measurement...................................................................................9
4.1.3 Touchscreen.........................................................................................................9
4.2 Switching on / off.......................................................................................................10
4.2.1 After each measurement.....................................................................................10
4.3 Buttons......................................................................................................................11
4.4 Customer and system management.........................................................................12
4.5 Operating instructions...............................................................................................12
4.6 Documentation menu................................................................................................13
5. Main menu.....................................................................................................................13
6. Selecting and entering customer data............................................................................14
7. Flue gas measurements ................................................................................................15
7.1 Connecting the flue gas probe..................................................................................15
7.2 Starting the flue gas measurement...........................................................................15
7.3 Selecting fuels, heat carrier temperature..................................................................15
7.4 Measuring combustion air temperature.....................................................................16
7.4.1 Measurement with the flue gas probe.................................................................16
7.4.2 Measurement with the combustion air sensor.....................................................16
7.5 Flue gas measurement.............................................................................................16
7.5.1 Average measurement........................................................................................17
7.5.2 Draft measurement.............................................................................................17
7.5.3 List of display values...........................................................................................17
8. Quick menu....................................................................................................................18
8.1 CO ambient...............................................................................................................18
8.2 Flue gas analysis Standard.......................................................................................18
8.3 Flue gas analysis average........................................................................................18
8.4 Flue gas analysis quick.............................................................................................19
8.5 Flue gas analysis – gas only.....................................................................................19
9. Pressure measurements................................................................................................20
9.1 Connection diagram..................................................................................................20
9.2 Pressure measurement.............................................................................................20
9.3 Tightness test............................................................................................................20

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9.4 Leak test...................................................................................................................22
9.4.1 Calculation of the gas pipe volume.....................................................................22
9.4.2 Starting the serviceability test.............................................................................23
9.4.3 Result of the serviceability test............................................................................23
10. Checklists ....................................................................................................................24
11. Data memory...............................................................................................................24
11.1 Saving measurements............................................................................................24
11.2 Data memory functions...........................................................................................25
11.3 Measurement data..................................................................................................25
11.4 Data storage information.........................................................................................25
11.5 Inspector table ........................................................................................................26
11.6 Deleting measurement data....................................................................................26
11.7 Deleting customers.................................................................................................26
12. Device information.......................................................................................................27
13. Settings........................................................................................................................27
13.1 Date and time..........................................................................................................28
13.2 Key beep.................................................................................................................28
13.3 MSI printer..............................................................................................................28
13.4 Display illumination.................................................................................................28
13.5 QWERTY keyboard ................................................................................................28
13.6 Automatic daylight saving time................................................................................28
13.7 Start screen ............................................................................................................29
13.8 PIN..........................................................................................................................29
13.9 Calorific value .........................................................................................................29
13.10 Extended fuel list...................................................................................................29
13.11 Federal Immission Control Ordinance (BImSchV) average value.........................29
13.12 NO
x
factor..............................................................................................................29
13.13 Start information....................................................................................................30
13.14 Printer footer texts.................................................................................................30
13.15 Language..............................................................................................................30
14. System messages........................................................................................................31
15. Power supply...............................................................................................................32
15.1 General power supply information ..........................................................................32
15.2 Charging batteries...................................................................................................32
16. Technical specifications...............................................................................................33
16.1 General technical specifications..............................................................................33
16.2 Technical specifications Exhaust and pressure measurements..............................34
17. PC measurement data management...........................................................................35
18. Consumables and accessories....................................................................................35

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1. Information
The manufacturer of this product, Dräger MSI GmbH, is referred to as Dräger MSI in the
following.
The displays shown in this manual are examples!
1.1 Warning signs
Symbol Text
Warning
Indication of a potential dangerous situation. Avoiding this warning can lead
to death or severe injuries.
Caution
Indication of a potential dangerous situation. Avoiding this warning can lead
to injuries or damages to the product or the environment. Can also be used
as a warning against improper use.
Information
Additional information regarding the use of the product.
1.2 For your safety
•Please read these operating instructions and those for the corresponding products
carefully before using the product.
•The operating instructions must be strictly followed. The user must completely under-
stand the instructions and follow them precisely. This product may only be used in
compliance with the designated use.
•Do not dispose of the operating instructions. Ensure safekeeping and proper use by
the users.
•Only trained and competent personnel are permitted to use this product.
•Observe local and national guidelines pertaining to this product.
•Maintenance work may only be conducted by Dräger MSI or by qualified personnel
trained by Dräger MSI- Otherwise the responsibility for the proper functioning of the
product after maintenance and for the validity of approvals is rejected by Dräger MSI.
•Only use original Dräger parts and accessories for maintenance work. Otherwise the
proper use of the product can be compromised.
•Do not use defective or incomplete products. Do not modify the product in any way.

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1.3 Safety instructions and warnings
•Do not operate the product if there is damage to the housing, power supply or supply
lines. Mark the product, to protect it against further use.
•Do not conduct any measurements, which could lead to contact with uninsulated, hot
parts.
•Only use the product appropriately and as intended and within the parameters spec-
ified in the technical specifications. The improper use of this product can result in
death, severe injuries or the destruction or damage of the product.
•Do not use this product in environments exposed to explosion hazards.
•This product is equipped with a magnetic holder. The magnetic field can be hazard-
ous to the health of persons with pacemakers.
•Do not open rechargeable batteries or batteries and do not throw them into fire.
•Store this product in a place at room temperature without exposure to solvents, plas-
ticizers agents, emissions or combustible materials.
•Only use this product in closed and dry rooms. Protect it against rain and moisture.
•Independent modifications to the product can lead to malfunctions and are prohibited
for safety reasons. The responsibility for the proper functioning of the product after
modification and for the validity of the certifications is otherwise refused by Dräger
MSI.
•This product is equipped with a magnetic holder. The magnetic field can damage
other products. Keep a safe distance from other products (e.g. mobiles, computers,
monitors, credit cards, memory cards, etc.).
1.4 Bluetooth
Changes or modifications not specifically approved by the responsible admissions
office can lead to the revocation of the operating license. Data transmission can be
destroyed by devices transmitting in the same ISM radio band, e.g. mobiles, WLAN,
microwaves, etc.
Among others, the use of radio communication is prohibited in aircraft and hospitals.

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1.5 Disclaimer
Dräger MSI does not assume any liability or warranty for damages or consequential
damage arising from non-compliance with technical regulations, instructions and rec-
ommendations. Dräger MSI and the sales companies are not liable for costs or dam-
ages resulting from the use of the product by the user or third parties, especially in the case
of improper use of the product. Neither Dräger MSI nor the sales companies are liable for
the incorrect use of the product.
1.6 Maintenance and servicing
To ensure proper functioning and measurement accuracy, calibration and adjustment
should be conducted annually by service specialists trained by the Dräger MSI
GmbH. If the measuring device is used for officially recognized measurements, the
measuring device must be inspected semi-annually by the office approved by the responsi-
ble authority for the calibration of proof tested measuring devices, to adhere to the minimum
requirements.
The device can be cleaned with a damp, not wet, cloth. Do not use any chemical cleaning
agents. Please make sure that the device connections are not clogged or dirty.
1.7 Disposal
The EU-wide directives for the disposal of electrical and electronic equipment apply.
Please observe the applicable local environmental regulations for disposal or return
the product to Dräger MSI or your national dealer for disposal. Defective rechargea-
ble batteries are considered hazardous waste and must be brought to the designated col-
lection points for disposal.

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2. Application
The Dräger FG7000 is an all-purpose, electronic multichannel measuring device for calibra-
tion and testing work on small and medium-sized incinerators.
It is not suitable for continuous operation or as a safety or alarm device.
A typical measurement cycle takes approx. 3 minutes.
All tests and measurements can be documented through print outs or storage.
The device employs combustible specific formulas, to calculate CO
2
and qA (exhaust gas
loss) combustion parameters. For this reason, these combustion parameters can only be
calculated for the combustible materials stored in the fuel table of the device. The following
fuels can be set:
Light fuel oil, natural gas, propane, heavy fuel oil, pellets, wood, brown coal, stone coal,
stone coal briquettes, stone coal coke, anthracite coal, biogas, butane, city gas, coke oven
gas
The service life of the sensors used in the Dräger FG7000 is typically 4 years for the O2,
CO and NO sensor. The pressure sensor has no limited service life under normal conditions
of use.
To avoid influencing the measuring accuracy of the sensors, the Dräger FG7000 must not
be exposed to solvents, combustible materials or plasticizers during operation or storage.
Only use a 5 V DC / 1 A USB power supply unit, to always fully charge the Dräger
FG7000 via the USB port.
Incomplete charging affects the charging capacity of the battery in the long run.
Do not conduct any measurements while the battery is charging.

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3. The product
3.1 The measuring device
Gas conditioning
Illuminated display
with touchscreen
USB port
Charge control,
IR transmitter
On/Off button
Connection external sensor
Pressure ports P+ and P- Connection for
combo-plug on the
exhaust probe

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3.2 The flue gas probe
Combo-plug
green LED yellow LED
The green LED indicates the exhaust probe being ready for measurement.
The yellow LED lights up when the highest temperature in the exhaust pipe is measured. It
starts blinking when moving away from the spot with the highest temperature.
A sensor for the flue draft measurement is integrated in the exhaust probe.
3.3 The multi-hole adapter
The multi-hole adapter is positioned on the probe tube of the exhaust probe for the meas-
urement and locked into place.
3.4 The annular adapter
The annular adapter is inserted on the probe tube of the exhaust probe for the measure-
ment and locked into place.

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4. First time use and operation
4.1 Preparation for first time use
Before using the measuring device for the first time, the integrity of all components must be
checked, e.g.:
− device does not exhibit any visible damage
− there is no condensation in the gas conditioner
− the gas conditioner filter is clean
− gas hoses do not exhibit any defects
− visual inspection of the probe
Insert the combo-plug on the flue gas probe into the probe inlet of the measuring device.
Prior to each measurement, make sure that a clean filter is inserted in the gas conditioner!
Only turn the Dräger FG7000 on, if the flue gas probe has fresh air. The zero signals of the
sensors are synchronized with the fresh air.
4.1.2 Prior to each measurement
The impermeability of the gas duct can be easily tested: Close the gas inlet of the probe
using the round cap. The probe has an integrated draft sensor. In the event of an impervious
gas duct, the device determines a high negative pressure through the pump output via the
integrated draft measurement, turns off the pump and creates the “probe is blocked!” mes-
sage on the display. This clearly indicates that the gas duct is impervious.
If this message is not displayed, the gas duct must be tested using a gas flow meter.
4.1.3 Touchscreen
The Dräger FG7000 is operated using the capacitive touchscreen display. You can execute
the tapping and swiping function on the screen with your finger. Menus and lists can be
moved up and down by up/down swiping gestures (scrolling).
Menus and list positions are highlighted by tapping on them. The selected item is activated
via the Select button or by tapping again.
Touching the display with sharp or pointy objects can lead to the destruction of the
display.

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4.2 Switching on / off
Switch on: Briefly press the On/Off button . The device switches on.
When switching the device on for the first time, please select your lan-
guage.
When the start screen is activated, it displays the model and a logo.
You can insert your logo with the measurement data management soft-
ware PC200P. The battery symbol indicates the charge state of the bat-
tery; information on whether the device is charged, a USB cable is con-
nected, whether Bluetooth is activated, whether the pump is running,
whether the start phase is completed and whether an exhaust probe or
an external sensor is connected is also shown.
You can access the start information or the icon main menu using the
Next button or by entering the PIN.
During the first 30 seconds, the device conducts a stabilization and a
system check. This is shown by the progress bar below the time display
and by the green square in the header. The measuring function cannot
be used during this time. Administrative functions can be used during
this time.
If scheduled maintenance is pending, the device issues a reminder one
month prior to the date of scheduled maintenance.
Switching off: Press the “Switch off” icon in the main menu or the
On/Off button. If a program is being used, the On/Off button switches
back to the main menu when pressed.
4.2.1 After each measurement
After the measurement, remove the probe from the exhaust gas flow and allow it to draw in
fresh air for 1-2 minutes, then switch off the device. Empty and clean the gas conditioner.
To open the gas conditioner, pull it out of the device; remove both plugs manually. Check
the filter disks and the filter fleece for soiling/contamination and if necessary, replace them.
Gas conditioner:
plug | condensate outlet | filter fleece | filter disk | filter cone | plug

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4.3 Buttons
Menu = opens the context menu for the selection and editing of system data
Select = enables the marked position
OK = confirms a selection
Done = leads to the next step of a function after an action
Next = leads to the next step of a function
Cancel = ends a function, switches to the main menu
>> = scrolls forwards, display switches to chart
<< = scrolls backwards, display switches to statistical data
Null = readjusts the zero point of the pressure sensor
Start = starts the measurement
Stop = stops the measurement
New = prepares a new measurement
Docu = switches to the documentation menu
Back = switches to the results display from the documentation menu
Customer = switches from the documentation menu to system selection
Print = prints the measurement result via the IR transmitter
Save = saves the measurement result in data memory
End = switches from the documentation menu to the main menu
Quit = prematurely ends a measurement period
Input = opens the input option for printer text

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4.4 Customer and system management
The Menu button opens a context menu. Depending on the menu item, the context menu
offers various editing options and commands. Customer data and comments can be entered
via an on-screen keyboard.
4.5 Operating instructions
Operating instructions are stored in the menu item Info.
Scroll between pages using >> and <<.
You can return to the menu item Info using the Done button.

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4.6 Documentation menu
After completion of a measurement, the documentation menu can be
accessed.
If no customer was selected before the measurement, a customer can
be selected here using Customer or a new customer can be created.
The measurement result is assigned to the customer via Save.
If no customer was selected, the measurement result is only stored un-
der the date and time.
The measurement result can be transmitted to an infrared printer via
the installed IR transmitter with Print.
5. Main menu
Selectable menu items are:
Flue gas Start flue gas measurement assistant
Pressure General pressure measurement
Check lists Select and edit checklist
Customers Open customer selection / management
Data memory View measurement database
Quick menu Quick measurements
Settings Change device and measurement settings and printer text, set clock
Info Device information, open manual
Switch off Switch off the measuring device

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6. Selecting and entering customer data
Customers and system data sets can be created and edited under the
Customer menu item. Conducted measurements can then be saved
under the created customers and systems. Customers and systems
can also be created after the measurement using a link in the docu-
mentation menu. Furthermore, the PC software provides the option of
creating customers and system data sets and transmitting them to the
measuring device.
Select: The selected customer number is accepted.
Menu: The context menu is opened.
Without: Measurements are saved with date and time.
New: New customer data can be created.
Edit: Existing data sets can be edited.
Search: A string can be searched for.
Delete: The selected data set can be deleted. This is only pos-
sible if there is no measurement data saved in the de-
vice.
The following can be stored: Customer number, name, system type, installation location,
system number, street, post code, city, customer name, customer street, customers post
code, customer city, customer phone number, boiler manufacturer, boiler type and year of
manufacture, boiler output, burner manufacturer, burner type and year of manufacture,
burner model and combustible material.
The acquired customer number applies to all subsequent measurements until the device is
switched off or another number is selected.

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7. Flue gas measurements
The flue gas measurement works with several measurement programs.
The individual measurement programs can be executed in any order.
An executed measurement program can be recognized by the green
check mark behind the menu item.
7.1 Connecting the flue gas probe
Insert the combo-plug on the probe into the device. The probe must be
able to draw in fresh air.
The gas outlet below the probe connection must be free andmay
not be closed or clogged!
7.2 Starting the flue gas measurement.
Switch on the Dräger FG7000, wait for system check to be completed and select Flue gas.
If the pump was switched off prior to selecting the flue gas measurement function, a brief
stabilization phase follows
7.3 Selecting fuels, heat carrier temperature
Prior to the measurement, please select the fuel
using the input functions for the boiler data, the
heat carrier temperature, the boiler output, the cal-
culation for the condensing boiler, etc.
The inspection of the system can be documented
with the entries for the visual inspection and the
comments.

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7.4 Measuring combustion air temperature
If a separate combustion air sensor is not being used, the combustion air data must be
measured using the flue gas probe prior to the flue gas measurement. This menu item can
be skipped in the case of a flue gas measurement using a separate combustion air sensor.
7.4.1 Measurement with the flue gas probe
Start the combustion air measurement with “Combust. Air”
Insert the flue gas probe into the opening of the combustion air supply
intended for testing or optionally, hold the exhaust probe in the indoor
air.
As soon as the combustion air values have stabilized, press Hold. If
the combustion air supply has an oxygen-content below 21%, this can
be an indicator for a leak in the exhaust pipe in the air/exhaust system.
7.4.2 Measurement with the combustion air sensor
As an alternative, the combustion air temperature can be measured
during the flue gas measurement. To do so, the optionally available
combustion air sensor must be connected prior to the measurement
and positioned in the combustion airflow.
In this case, the combustion air temperature is accepted when determining the measure-
ment readings or during averaging.
7.5 Flue gas measurement
There are areas in the exhaust gas flow, which are only partially mixed
with exhaust. Therefore, it is necessary to obtain the sample from the
core stream. The core stream is distinguished by a maximum exhaust
temperature and a minimum oxygen concentration.
Start the flue gas measurement with “Flue gas”.
Now, insert the flue gas probe into the exhaust pipe, move it in the ex-
haust gas flow and position it, so that the tip of the probe is in the core
stream (highest gas temperature, lowest oxygen concentration). In the
process, you can use the yellow LED in the flue gas probe for orienta-
tion. The LED lights up when the maximum exhaust temperature has
been reached; if you move the flue gas probe out of the core stream,
the LED starts blinking. After you have found the core stream and the
readings have stabilized, secure the flue gas probe in this optimum po-
sition with the probe cone. A summary of the currently measured com-
bustion values is shown. Now, press the Hold button.
If you press the currently measured or calculated value, the display switches to the diagram.

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7.5.1 Average measurement
The 1st Federal Immission Control Ordinance (BImSchV) requires the
simultaneous determination of oxygen content of the exhaust and ex-
haust temperature as an average value for a duration of 30 seconds.
Insofar as the BImSchV measurement was activated in the settings,
you can start the 30-second averaging process using Start; then, you
do not need to use Hold.
The progress of the averaging process is shown using a vertical pro-
gress bar on the right side of the screen. After completion of the aver-
aging process, the calculated measurements are highlighted in yellow
on the right side of the screen.
7.5.2 Draft measurement
Draft measurement takes place simultaneously during the flue gas measurement and is also
included in the averaging process.
7.5.3 List of display values
T-A Combustion air temperature
T-G Exhaust gas temperature
O2 Measured oxygen content
CO Measured carbon monoxide content
NO Measured nitrogen monoxide content
P-D Measured flue draft
CO
2
Measured carbon dioxide
qA Determined exhaust gas loss of exhaust gas
CO-0 Determined carbon monoxide content relative to 0 vol. % oxygen
Eta Determined combustion-technical efficiency of combustion
T-Tau Determined temperature of the dew point
Lambda Determined combustion air ratio
NOx NOx value calculated from NO shown as NO2
O2-A Measured oxygen content of combustion air
Smoke no. Average of entered smoke numbers
Oil der. Consideration of oil derivatives
O2-S Measured oxygen content in the annular passage
T-S Measured combustion air temperature in the annular passage
P-S Measured pressure in the annular passage

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8. Quick menu
The quick menu bundles the most important measurements.
It allows the following to be performed:
8.1 CO ambient
The regulations of some countries require that the tightness of a com-
bustion installation must be ensured by a measurement of the CO con-
centration in the ambient air. For the CO ambient air measurement the
Dräger FG7000 doesn’t need a separate CO sensor. At a location with
fresh air, without CO content, the value has to be 0 ppm. If the reading
is not 0 ppm, pull off the Combo-plug of the gas probe from the device,
wait for a short while and press Null. The now displayed value will be
set to zero. This zero point is independent from the CO zero point of
the normal flue gas measurement.
8.2 Flue gas analysis Standard
After you selected a fuel, a Standard flue gas measurement will be
performed. All relevant measurement values and calculations will be
displayed. If the measurement is performed at a calorific value boiler,
you should activate the calorific value setting in the general settings.
Only in this case negative losses and efficiency higher than 100% will
be calculated.
8.3 Flue gas analysis average
In many cases average value measurements are used to get repro-
ducible results, despite of time alterable combustion states. For this is
a averaging in certain time called. E.g. the German regulation 1st
BImSchV calls for averaging of 30 s average values. For solid fuels it
calls for averaging of 15 min average values. After selecting the fuel,
you can select the averaging time from a table:
30 s, 1 min, 5 min, 15 min, 30 min or 60 min.

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8.4 Flue gas analysis quick
The flue gas analysis quick allows to display only measured values
without fuel selection and no fuel depending calculations. Displayed
values: flue gas temperature, measured oxygen, measured carbon
monoxide, measured nitrogen monoxide (option), measured induced
draft, and determined combustion air ratio.
8.5 Flue gas analysis – gas only
Before starting the measurement, which is displayed in mg/Nm3, mg/MJ, and mg/kWh, you
have to select the fuel and the O
2
reference value. The standard O2 reference value for a
fuel is preset.