E Instruments BTU900 User manual

BTU900 BTU900
Portable Combustion Gas Analyzers

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1.0 INTRODUCTION 05
1.1 General Description of the Combustion Analyzer 05
1.2 General features of the Combustion Gas Analyzer 05
1.3 BTU900 Main configurations 06
2.0 TECHNICAL SPECIFICATIONS 07
2.1 Technical Specifications 07
2.2 Overview of Flue Gas Analyzer Components 08
2.3 Measurement and AccuracyRanges 11
3.0 USING THE COMBUSTION FLUE GAS ANALYZER 12
3.1 Preliminaryoperations 12
3.2 Warnings 12
3.3 Analyzer power supply 12
3.3.1 Checking and replacing the batteries 12
3.3.2 Use with external power pack 12
4.0 OPERATION 14
4.1 Working principle 14
4.2 Measurement cells 14
4.3 Connecting the Sampling probe 14
4.4 Condensate (water) trap and fine dust filter 14
4.5 Connecting the SMART Incoming Air temperature probe 15
4.6 Connecting the TcK probe 15
4.7 Keypad overview 16
4.8 Info Menu 17
4.8.1 Flow Chart - Info Menu 18
4.9 Analysis configurationmenu 20
4.9.1 Flow Chart - Analysis configuration menu 22
4.10 Instrument configuration menu 27
4.10.1 Flow Chart - Instrument configuration menu 28
4.11 Memory Menu 30
4.11.1 Flow Chart - MemoryMenu 31
4.12 Print Menu 33
4.12.1 Flow Chart - Print Menu 34
4.13 Analysis Menu 36
4.13.1 Zoom Menu 36
4.13.2 Flow Chart - Analysis Menu (Zoom) 37
4.14 Draft Menu 39
4.14.1 Flow Chart - Draft Menu 39
4.15 Readings Menu 40
4.15.1 Flow Chart - Readings Menu 41
4.16 Flow Chart - Configure Analysis Menu 42
4.17 Flue Gas Analysis 43
4.17.1 Switching on the instrument and auto-calibration 43
4.17.2 Inserting the probe inside thestack 43
4.17.3 Flue Gas Analysis 43
4.17.4 End of Analysis 44
4.17.5 Flow Chart - Flue Gas Analysis 45
4.18 Measuring the Differential Pressure (optional kit) 49
TABLE OF CONTENTS
TABLE OF CONTENTS TABLE OF CONTENTS
TABLE OF CONTENTS

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5.0 SENSORS 50
5.1 Sensor Arrangement 50
5.2 Sensor types and relevant positioning 50
5.3 Gas sensor life 50
5.4 Gas sensor life table 50
5.5 Expandabilityto 3 sensors 51
6.0 MAINTENANCE 52
6.1 Routine maintenance 52
6.2 Preventive maintenance 52
6.3 Cleaning the sample probe 52
6.4 Maintaining the water trap / filter unit 52
6.5 Replacing the particulate filter 53
6.6 Replacing the gas sensors 53
6.7 On-site recalibration 57
6.7.1 Flow Chart - On-site recalibration 57
6.8 Replacing the batterypack 60
7.0 TROUBLESHOOTING 61
7.1 Troubleshooting guide 61
8.0 SPARE PARTS ANDTECHNICAL ASSISTANCE 63
8.1 Spare parts 63
8.2 Accessories 63
8.3 Service Center 63
TABLE OF CONTENTS
TABLE OF CONTENTS TABLE OF CONTENTS
TABLE OF CONTENTS

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1.1 General Description of the Combustion Analyzer
The design of the handheld combustion analyzer “BTU900” isclean and ergonomic with an extremely clear and
user-friendly keypad.
The “BTU900” immediately suggests just how even the most sophisticated engineering can give life to an
incredibly comfortable and easy to use work instrument.
Devised to analyse flue gases, monitor the pollutantsemitted and measure environmental parameters, “BTU900”
uses two electrochemical cellsthat provide the oxygen and carbon monoxide valueswhile a third cell (optional) is
used to measure the pollutantsNO and NOx.
Two external sensorsmeasure the environmental parameters; it is also possible to measure flue draft and carbon
blackand, with the measuring range of up to 200hPa, system pressure and pressure in the combustion chamber
can be measured and the pressure switches checked.
“BTU900” is designed for seven main types of combustible substances, among which natural gas, LPG, Diesel
fuel and fuel oil. Another 16 types of which the chemical composition is known can be entered in its memory.
“BTU900” functions include storing and averaging the measurements acquired, printing the results (through IR
communication interface) and connecting to the computer for filing the data, using a USB connection.
The memory can store 300 complete analysesand the data downloaded onto a PC by means of dedicated SW
and a mini-USB serial communication cable. It is also interesting to note that “BTU900” has just one “Li-Ion”
rechargeable battery pack used for powering the instrument and the printer; it also has a luminousand large (42
x 60mm)LCD displayboasting excellent readabilitythanks to its backlighting and also to the zoom function.
Another characteristic that distinguishesit from other similar productsin the market is the fact the power supply
that comes with the product can carry out the dual function of battery charger and power supply for the
instrument which means the user can carry out analyseseven if the batteriesare completely flat.
Asfar asconcernsmaintenance, it isuseful to know that the user can replace the sensors himself without having
to send the instrument backto the technical Service center: in fact, the sensors are pre-calibrated and “BTU900”
doesnot need recalibrating.
Moreover:
• Operator interface: user-friendly - so much so that it can be used without the instruction manual.
• Luminous and large LCD display: easy readability thanksto the Zoom function and effective backlighting.
• Infrared interface: optional external impact printerisavailable.
• One battery pack: rechargeable for powering the instrument and the printer, indicating the charge level and is
accessible from outside.
• Pneumatic input connectors (gas and pressure/draft) staying inside the profile of the instrument: for
greater resistance to knocks.
• Pre-Calibrated sensors, directly replaceable by the user.
1.2 General features of the Combustion Flue Gas Analyzer
The BTU900 is a portable flue gas analyzer that was meticulously designed to meet statutory requirements and
specific customer demands. It maybe provided in a rugged ABS carry case or waterproof shoulder bag.
The instrument contains one single board with all the basic circuitry, pre-calibrated measuring cells, sampling
pump, silicone keypad, backlit graphic LCD display, and an high-capacity rechargeable Li-Ion battery pack. The
two halvesof the case are firmly secured byfour screwson the rear of the instrument.
The pneumatic path and measuring cells inclusive of electronicmicromodule are located on the back side of the
plastic case and are easily accessed for maintenance and replacement by removing the cover carrying the
functionslabel.
The pneumatic connectors for flue gas sampling and pressure/draft measurement as well as the flue gas
thermocouple connector and the mini-DIN serial interface are installed on the lowerend of the instrument.
On the left hand side there isa plug for connecting the external power supply, the 8-pin min-DIN, the IR interface
and the mini-USB connectors.
The 8-pin mini-DIN connector can be used as a serial interface or as an optional probe interface for
Deprimometer orPt100 combustion air probe.
The user interface consists of a constantly active backlit graphic LCD displayand silicone keypad. Menu screens
and all user messages can be set in the language of the country where it is used; this can be selected through
the menu in one of the available ones. Use of the analyzer issimplified by symbol keysthat give direct access to
main instrument functions. Shifting between the various menu screens is easy and user-friendly thanks to four
cursor keys, an ' ' keyand ' ' key.
1.0 INTRODUCTION
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BTU900 -HE
BTU900 -Oil
O 2 SENSOR 
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CO (Low H 2) SENSOR 
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NO SENSOR Optional Optional
CALIBRATION CERTIFICATE 
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INSTRUCTION MANUAL 
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FLUE SAMPLING PROBE
300mm (12”) + 10’ Dual Hose 
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PRESSURE MANOMETER 
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BATTERY CHARGER 
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MEMORY + PC SOFTWARE 
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BTU900 -NOx
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BTU900 -HE-NOx
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SMOKE PUMP KIT Optional 
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Optional
BLUETOOTH 
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1.3 BTU900 Main configurations
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2.0 TECHNICAL SPECIFICATIONS
2.1 Technical Specifications
Autozero: Manual autozero cycle (without probe inserted in the stack).
Self-diagnosis: All the functions and internal functionsare checked and anomalies signalled.
Type of Fuels/Oils: 7 predefined by the factory and 16 that can be programmed by the user.
Power: Li-Ion battery pack with internal protection circuit.
Battery charger: External battery charger.
Battery autonomy: 12 hoursof continuousoperation from fully charged battery.
Charging time: 4 hours for charging from 0% to 90% (5 hoursfor 100% charge).
Internal data memory: 300 complete data analysis, time and name of the customer can be stored.
User data: 3 programmable user names.
Print-out heading: 4 lines x 24 characters, customisable by the user.
Display: Graphic backlit LCD, measuring 42 x60 mm.
Communication port: USB with mini-USB connector.
IR interface for external printerusing HP-IR protocol (optional).
Bluetooth (optional): Communication range: <100 meters(free field)
Manufacturer: FREE2MOVE
Model: F2M03GLA - CLASS 1
Bluetooth SIG Qualification Design (QDL) Certificate: B012541
Certification EC-R & TTE: 0681
Line filter: With replaceable cartridge, 99% efficient with 20um particles.
Suction pump: 1.2 l/min headsat the flue up to 135hPa.
Condensate trap: Outside the instrument.
Carbon black: Using an optional external Smoke hand pump; it is possible to simply enter and
print the Smoke indexresults.
Condensing boiler efficiency: Automatic recognition of the condensing boiler, with calculation and printout of
efficiency (>100%) on the LHV (Lower Heating Value) in accordance with
UNI10389-1.
Environmental gases: Measurement and separate printout of the ambient CO and NO values.
Draft test: Draft tested as per the UNI 10845 standard. Using the external draft gauge
AACDP02 the resolution is0.1 Pa with 0.5 Pa accuracy.
Operating temperature range: -5°C to +45°C (23°F to 113°F)
Storage temperature range: -20°C to +50°C (-4°Fto 122°F)
Operating humidity range: 20% to 80% RH
Protection grade: IP42
Air pressure: Atmospheric
Outerdimensions: Analyzer: 220 x 100 x52 mm (H x W x D)
8.6 x3.9 x2 inches (H x W x D)
Case: 225 x 109 x 69.5 mm (H x W x D)
8.8 x4.3 x2.7 inches(H x W x D)
Weight: Analyzer: ~ 19.4 oz
Compliant with the CEI-EN50379-2 European Standard.
External IR printer (optional):
• With thermal paper, 24 characters, data transmission through IRinterface and HPir standard protocol.
• Paper roll size: 58mm x 40mm (paper length 25 meters, about 120 report tickets).
• Power supply: with internal rechargeable Ni-MH batteries.
• External battery charger prov.ided with printer.
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LEGEND
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Keypad
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Display
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Flue GasSampling probe
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Condensate separatorand fine dust filter unit (WaterTrap Assembly)
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Compensated male connector of the fumesexhaust temperature probe
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SMART Incoming Air temperature probe
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P- connector (negative input for measuring differential pressure)
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A - connector (sample probe input by means of the water trap)
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P+ connector (positive input formeasuring draft)
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Battery charger socket
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Serial cable socket for connecting to the draft gauge and to the ancillary probes
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Temperature Tc-K female connector
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IR communication port
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Mini-USB socket for connecting to a PC
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2.2 Overview of Flue Gas Analyzer Components
Fig. 2.2
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Keypad
Silicone rubber keypad featuring main control functions (pos. in Fig. 2.2).
Display
Backlit 128 x 64 pixel LCD display (pos. in Fig. 2.2), with 8 linesx 20 charactersavailable. Allowsthe user to
view the measured parameters in the most comfortable format; a Zoom function displays the measured valuesin
magnified form.
CAUTION: If the instrument is exposed to extremely high or extremely low temperatures, the quality of
the display may be temporarily impaired. Display appearance may be improved by acting on the contrast
key.
Rechargeable Battery Pack
The instrument isprovided with a 12VDC, 2A power supply packto charge the internal batteries.
The socket for connecting the battery charger to the instrument isshown asitem in Fig. 2.2. Once the charge
isstarted the display turns on and showsthe charge status.
Serial connector (Mini Din 8-pole)
In of Fig.2.2 we find the socket of the serial cable for connecting the instrument to an external probe, for
example, to the draft gauge (optional),or to the ionization current probe (optional).
Mini/USBconnector
In of Fig.2.2 we find the socket of the serial cable for connecting the instrument to a personal computer.
Sample pump
The sample pump located inside the instrument is a DC-motor-driven diaphragm pump, powered by the
instrument, and is such asto obtain optimal flowof the sampled gasbeing analyzed.
Flue Gas SamplingProbe
Stainless steel probe with plastic handgrip (see of Fig.2.2). The Standard Length of the steel probes is 12
inches (300 mm). Other available lengths are 180 mm, 750 mm and 1000 mm with adapter cone for the flue
hole, diameter 8-22 mm. A flexible probe is also available with a 300 mm long tip, for measuring inside flues
where the fumespicking point isdifficult to reach. All probes have a nominal outside diameter of 8 mm.
Connection to an analyzer via a 3-meter rubber hose and replaceable condensate separator and fine dust filter
unit (see of Fig.2.2).
Measurement Cells
The instrument uses pre-calibrated gas sensors of the long-lasting FLEX-Sensor series for measuring oxygen
(O
2 ), carbon monoxide CO and nitrogen oxide (NO). Up to 4 alarmscan be programmed with visual and acoustic
warning forthe same number of measuring parameters.
The measuring cells are the electrochemical type. The UNI10389-1 standard prescribes that the instrument must
be calibrated once a year byan authorized laboratory to issue calibration certificates. When the cellsare flat they
can be replaced easily by the user without having to send the instrument away and without complicated
calibration proceduresrequiring sample mixturesasthey are supplied already calibrated.
E Instrumentsdoes, however, certify measurement accuracy only when a calibration certificate hasbeen issued
by itsown laboratory or byan authorized laboratory.
Temperature sensors
Flue gas temperature ismeasured by meansof a thermocouple inserted in the tip of the probe.
The thermocouple is connected to the instrument via a compensated cable (pos. in Fig. 2.2.) housed in a
special seating in the rubberhose of the sample probe.
Connection to the instrument isachieved via a temperature-compensated male connector.
The cold junction is compensated by a Pt 100 resistance thermometer which measures the temperature at the
thermocouple connector.
The type K thermocouple (nickel/nickel chromium) permits continuous measurements up to 800°C. If special-
purpose probesare used, the instrument is able to measure temperaturesas high as 999.9°C.
A Pt 100 resistance thermometer located inside the instrument measuresthe internal temperature; thissensor is
also used to measure the ambient temperature.
Should the user want to measure the combustion air temperature directly in the intake duct, the optional remote
Pt 100 sensor must be used - thismeasurement isrecommended formore precise calculation of plant efficiency.
Remote temperature probe
The temperature probe consistsof a Pt 100 probe, complete with 2 m cable and 7.5/17 mm pit adapter (pos.
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in Fig. 2.2).This probe is used to measure the combustion air temperature, within a range of -10°C to +100°C,
when boilerefficiencyisto be calculated precisely.
Pressure sensor
The instrument features an internal piezoresistive sensor to measure the stack draft (negative pressure) and
other parameters if required (gas network pressure, pressure drop across filters etc.).The user can switch from
flue gasanalysisto this reading by simplypressing a key.
Sample and + / - pressure inputs
The positive input P+ and negative input P-are used simultaneously to measure differential pressure.
Pos. in Fig. 2.2 isthe input of the sample probe complete with water separatorand particulate filter. Pos. and
in Fig. 2.2 are respectively the positive and negative internal differential pressure sensor inputs.
The positive input P+ isused to measure pressure in general. The positive input P+ isused to measure
draft in accordance with standard UNI10845; the branch of the fume exhaust probe without the anti-condensation
filter should be connected to it for simultaneousdraft measurement and combustion analysis.
Fuel types
The instrument has been programmed with the technical characteristics that are typical of seven common fuels.
By means of the optional PC configuration program, thislist and the relative coefficients may be modified for up
to a total of 10 fuels.
The following chart, derived from standard UNI 10389-1, lists the coefficients of the seven memorized fuels, used
for calculating lossesand efficiencies.
Smoke measurements
It ispossible to enter the smoke valuesmeasured according to the standard Smoke index scale. The instrument
will calculate the average and print the resultsin the analysisreport.
An external smoke pump, available asan optional, must be used to correctly take thismeasurement.
Measuring ambient /room air CO (CarbonMonoxide)
Probe for monitoring the concentration of CO and checking safe conditions in the boiler room. An acoustic and
visual warning signal isgiven if the thresholdsare exceeded according to the OSHA levels.
Internal gas leak detector sensor
Thissensor searchesfor explosive gasleaksin the pipes.
External low pressure sensor (draft gauge)
Thissensor isa particular draft gauge with precision (±0.5 Pa)and resolution (0.1 Pa) characteristicshigher than
those of the sensor installed inside the instrument. This makes it possible to comply with the UNI 10845 standard.
Burner pressure verification probe
It must be used to measure burner pressure of the gas-powered boiler so it can be regulated in real time. It is
made of a silicone tube, 8x4mm and 1 metre long, complete with connector for connecting to the analyzer.
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Coefficients for calculating combustion efficiency
A1 A2 B CO 2 t % Fuel
0,280 0,3276 0,0090 11,70 Natural gas
0,0305 0,4789 0,0066 15,70 #2 Oil
0,0306 0,4835 0,0066 15,80 #4 Oil
0,0305 0,4789 0,0066 15,70 Diesel
0,0354 0,6700 0,0071 19,01 Wood/Pellets 8%
0,0320 0,5952 0,0000 18,60 Coal
0,0305 0,4789 0,0066 15,70 Bio-Fuel 5%
0,0277 0,4500 0,0073 13,80 LPG
0,0277 0,3795 0,0073 14,00 Butane
0,0277 0,3878 0,0073 13,70 Propane
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Probe for measuring the ionizationcurrent
With this special probe it ispossible to measure the ionization current of a boiler and checkitsvalue depending
on the boiler’stechnical features.
Calibration certificate
The instrument is calibrated by comparing to National Calibration Standards provided by a Metrology Lab.,
certified periodicallybyinternationallyrecognized laboratories.
A calibration certificate is provided with each and everyinstrument where every parameteris accompanied by the
relevant nominal value, measured value, permissible error tolerances and measured error.
Electromagnetic compatibility
The instrument was designed to comply with Council Directive 2004/108/EC governing electromagnetic
compatibility.
2.3 Measurement Ranges and Accuracies
All data relative to concentration accuracies are referred to an instrument operating at a constant temperature
within the correct operating range (-5°C .. +45°C), being in operation for at least 15 minutes, powered by its
internal batteryand after completion of auto-zero procedure.
Notes: (1) The maximumCO
2
value displayed dependson the type of fuel.
(2) Stated precision includes errorof the external sensor RTD Pt100 classA DIN 43760 (1980).
(3) Stated precision includes errorof the external sensor type K thermocouple class1 IEC584.
(4) Pressuresgreater than 300 inH 2 O may permanentlydamage sensors orimpair their characteristics.
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MEASUREMENT SENSOR RANGE RESOLUTION ACCURACY
O 2 Electrochemical sensor 0 .. 25.0% vol 0.1% vol ±0.2% vol
CO
With low sensitivityto
H2
Electrochemical sensor 0 .. 8000 ppm 1ppm ±20 ppm 0 .. 400 ppm
±5% measured value 201 .. 4000 ppm
±10% measured value 4001 .. 8000 ppm
NO Electrochemical sensor 0 .. 5000 ppm 1ppm ±5 ppm 0 .. 100ppm
±5% measured value 101 .. 5000 ppm
NOx Calculated
CO 2 Calculated 0.. 99.9% vol 0.1% vol
Air temperature Pt100sensor -20.0 .. 120.0 °C 0.1 °C ±0.5 °C
Fluegas temperature TcK sensor -100.0 .. 1250.0 °C 0.1 °C ±0.5°C 0 .. 10 0 °C
±0.5% measured value 101 .. 1250 °C
Pressure
(draft & differential)
Piezoelectric sensor -4.014.. 80.292 inH 2 O 0.004inH 2 O ±1% measured value -4.014 .. 0.806 inH
2 O
±0.008 inH 2 O -0.802 .. 0.802inH 2 O
±1% measured value 0.806.. 0.292inH
2 O
Differential temperature Calculated 0.. 1250.0°C 0.1 °C
Air index Calculated 0.00.. 9.50 0.01
Excess air Calculated 0.. 850 % 1%
Stack loss Calculated 0.0 .. 100.0% 0.1%
Efficiency Calculated 0.0 .. 100.0% 0.1%
Efficiency
(condensing)
Calculated 0.0 .. 120.0% 0.1%
Smoke index External instrument 0.. 9
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3.0 USING THE FLUE GAS ANALYZER
3.1 Preliminary operations
Remove the instrument from its packing and check it for damage. Make sure that the content correspondsto the
items ordered. If signs of tampering or damage are noticed, notify the E Instruments service center or agent
immediately and keep the original packing. A label at the rear of the analyzer bearsthe serial number. Thisserial
number should always be stated when requesting technical assistance, spare partsor clarification on the product
or itsuse.
E Instrumentsmaintainsan updated database for each and every instrument.
Before using the instrument for the first time it is recommended to charge the battery for 12 hours with the
instrument turned off.
3.2 Warnings
• Use the instrument with an ambient temperature between -5 and +45°C.
• When it has finished being used, before turning the instrument off remove the probe and let isaspirate ambient
clean air for at least 30 seconds to purge the pneumatic path from all tracesof fumes.
• Do not use the instrument if the filters are clogged or damp.
• Before putting the measuring probe back in its case after use, make sure it is has cooled down enough and
there is no condensate in the tube. It might be necessary to periodically disconnect the filter and the
condensate separator and blow compressed air inside the tube to remove all residues.
• Remember to have the instrument checked and calibrated once a year in order to comply with the existing
standards.
3.3 Analyzer power supply
The instrument contains a high-capacity LiIon rechargeable battery.
The battery feeds the instrument any other probes or remote devices that may be connected. The instrument
runs for approximately 18 hours. Should the battery be too low to effect the necessary measurements, the
instrument can be hooked up to the mains via the power pack provided, allowing operations (and analysis) to
proceed. The battery will be recharged whilst the instrument isbeing used.
The battery charging cycle takesup to 3 hoursfor a complete charge and finishesautomatically.
ATTENTION: If the instrument is not going to be used for a long time we suggest recharging it at least
once every 2 months.
3.3.1Checking and replacing the batteries
The statusof the internal battery can be checked during instrument auto-calibration or even after, if necessary, by
pressing the information menu and accessing the “battery capacity” submenu. The menu displays the
battery’s residual capacity and voltage. If battery charge appears to be low, let it discharge completely and then
carry out a full 100% charge cycle by connecting the instrument to the power pack for 3 hours. If the problem
persists, replace the battery packwith a E Instrumentsoriginal or contact the SERVICE CENTER to carry out the
necessary repairs.
The average life of the battery pack is 500 charging/discharging cycles. To take advantage of this to the fullest
capability it isadvisable to alwaysuse the instrument powered by the internal batteries and to charge it only when
it gives the battery flat message.
3.3.2Use with external power pack
The instrument can workwith the batteriesfully discharged by connecting the external power packprovided.
Kindly note that while the battery is charging, some heat is generated which increases the instrument’s internal
temperature. This may lower the accuracy of some readings. The air temperature must be measured using the
air temperature probe since the internal sensor might lie at a different temperature with respect to ambient.
ATTENTION
THE INSTRUMENT IS SHIPPED WITH THE BATTERY HALF CHARGED SO IT IS ADVISABLE TO
CHARGE IT COMPLETELY BEFORE USE, TAKING 3 HOURS.
IT IS ADVISABLE TO CHARGE THE BATTERY AT AN AMBIENT TEMPERATURE RANGING BETWEEN
50°F AND 85°F (10°C AND 30°C).
ATTENTION
IF THE INSTRUMENT HAS BEEN KEPT AT VERY LOW TEMPERATURES (BELOW OPERATING
TEMPERATURES) WE SUGGEST WAITING A WHILE (1 HOUR) BEFORE SWITCHING IT ON TO HELP
THE SYSTEM’S THERMAL BALANCE AND TO PREVENT CONDENSATE FORMING IN THE PNEUMATIC
CIRCUIT.
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ATTENTION
THE POWER SUPPLY/BATTERY CHARGER IS A SWITCHING TYPE ONE.
THE APPLICABLE INPUTVOLTAGE RANGES BETWEEN 90Vac AND 264Vac.
INPUTFREQUENCY: 50-60Hz.
THE LOW VOLTAGE OUTPUT IS 12 VOLTWITH AN OUTPUT CURRENTGREATER THAN 1.5A.
LOW VOLTAGE SUPPLY CONNECTOR: DC PLUG 2.1x5.5x9 mm. WITH CENTRAL POSITIVE AND
OUTER BARREL GROUND.
IF AN UNSUITABLE POWER SUPPLY IS CONNECTED ITCAN DAMAGE THE INSTRUMENT; USE ONLY
THE ONE SUPPLIED WITH IT.
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4.1 Working principle
The gas sample istaken in through the sample probe, bya diaphragm suction pump inside the instrument.
The measuring probe hasa sliding cone that allowsthe probe to be inserted in holeswith a diameter of 11 mm to
16 mm and to adjust the immersion depth: the sampling point must be roughly in the center of the flue pipe/
stack.
The gas sample is cleaned of humidityand impurities by a condensate trap and filter positioned along the rubber
hose that connects the probe to the analyzer.
The gas components are then analyzed by the electrochemical sensors.
Oxygen (%O 2 ) is measured with an electrochemical cell that acts like a battery which, over time, is apt to lose
sensitivity.
The toxicgases(CO, NO) are measured with electrochemical sensorsthat are not subject to natural deterioration
being intrinsicallylacking of oxidation processes.
The electrochemical cell guarantees high precision results in a time interval of up to about 60 minutes during
which the instrument can be considered very stable. When measurement is going to take a long time, we suggest
auto-zeroing the instrument again and flushing the inside of the pneumatic circuit for three minutes with clean air.
During the zero calibrating phase, the instrument aspiratesclean air from the environment and detectsthe cells’
drifts from zero (20.95% for the O2 cell), then compares them with the programmed values and compensates
them. The pressure sensor autozero must, in all cases, be done manually prior to measuring pressure.
The values measured and calculated by the microprocessor are viewed on the LCD display which is backlit to
ensure easy reading even when lighting is poor.
4.2 Measurement cells
The measurement cells are electrochemical cells made up of an anode, a cathode, and an electrolytic solution,
which depends on the type of gas to be analyzed. The gas penetrates the cell through a selective diffusion
membrane and generates an electric current proportional to the absorbed gas. Such current is measured,
digitalized, temperature-compensated, processed by the microprocessor, and displayed.
The gas shall not be at a pressure such to damage or destroy sensors. The maximum estimated allowed
pressure is ±100hPa gage.
The response timesof the measurement cellsused in the analyzer are:
O 2 = 50 sec. at 90% of the measured value
CO = 60 sec. at 90% of the measured value
NO = 40 sec. at 90% of the measured value
It is therefore suggested to wait 5 minutes(anyway not less than 3 minutes) in order to get reliable analysis data.
If sensors of poison gasesare submitted to concentrationshigher than 50% of theirmeasurement range formore
than 10 minutes continuously, they can show up to ±2% drift as well as a longer time to return to zero. In this
case, before turning off the analyzer, it is advisable to wait for the measured value be lower than 20ppm by
disconnecting the probe and letting the pump run in clean air.
4.3 Connecting the sample probe
The sampling probe is made up of an INOX steel tube with a plastic hand grip and an internal K-type
thermocouple (Ni-NiCr) for measuring the fumes temperature up to 800°C. The probe is connected to the
analyzer through a double flexible hose, a filter group and a compensated cable for the thermocouple. The
polarized connector of the thermocouple is to be connected to the special outlet on the lower side of the
instrument. It isnot possible to perform a wrong connection thanksto the different width of contacts. Connect the
shorter tube of the probe to the filter group (fine dust/condensate trap) which, in turn, shall be connected to the
central connector of the instrument marked with letter “A”. Connect the longer tube, ending with a male
connector, to the negative pressure input of the instrument marked with letter “P-”. The different diameter of
connectors does not permit any wrong connections; thispermits to avoid anydamagesto the instrument.
4.4 Condensate trap and fine dust filter
The sample gasto be analyzed shall reach the measurement cellsafter being properly dehumidified and purified
from the residual combustion products. To this purpose, a condensate trap is used, which consists of a
transparent polycarbonate cylinder placed along the rubber hose of the sampling probe. Its purpose is to
decrease the air speed so that the heavier fine dust particles can precipitate and the vapor in the combustion
gasescan condensate.
The condensate trap must be always kept in the vertical position in order to prevent condensate from touching
the measurement cells. This is also the reason why it is important to periodically drain the trap, anyhow at the
end of each test (see chapter 'MAINTENANCE').
A replaceable low-porosity line filter is placed after the condensate trap aimed at keeping the solid particles
suspended in the gases. It is recommended to replace the filter whenever visibly dirty (see chapter
'MAINTENANCE').
4.0 OPERATION
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4.5 Connecting the combustion air temperature probe
Should you need to measure the actual combustion air temperature and the analyzerisnot in the place where
the combustion air is to be taken (important for a correct calculation of the burner efficiency), you shall use the
remote probe.
The remote probe is made up of a Pt100 thermal resistance equipped with cable (3 meters long) and connector
for its connection to the analyzer.
4.6 Connecting the TcK probe
Using the same input as for the K thermocouple (the same used for flue temperature), it is possible to measure
the water delivery and return temperature by connecting some special probes. If temperature is taken on the
pipe, it issuggested to use arcprobes with a suitable diameter.
ATTENTION
KEEP THE CONDENSATE TRAP IN THE VERTICAL POSITION DURING THE ANALYSIS; A WRONG
POSITIONING MAY CAUSE CONDENSATE TO LEAK INTO IN THE INSTRUMENT AND DAMAGE
SENSORS.
AFTER EACH ANALYSIS, CHECK FOR ANY PRESENCE OF WATER IN THE CONDENSATE
COLLECTION BOWL AND REMOVE IT, IF ANY. PUTTHE PROBE BACK IN THE CASE ONLY AFTER YOU
HAVE REMOVED CONDENSATE FROM THE TUBE AND THE EXPANSION TANK (SEE CHAPTER
'MAINTENANCE').
REPLACE THE FINE DUST FILTER IF ITIS VISIBLY DIRTY OR WET (SEE CHAPTER 'MAINTENANCE')
DO NOT PERFORM ANY MEASUREMENT WHEN THE FILTER IS REMOVED OR DIRTY IN ORDER TO
AVOID ANY RISK OFPERMANENTDAMAGES ON SENSORS.
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4.7 Keypad overview
WARNING: to turn-on / off the instrument it is necessary to press and hold the On/Off
button for at least 2 seconds.
Configure / Info Menu
On / Off
MeasurementsMenu
Analysis Menu
Print Menu
Zoom IN
Select / Modify
Zoom OUT
Cancel / Exit
Confirm
MemoryMenu
Draft Menu
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Thismenu provides information regarding instrument status:
Battery capacity:
Showsthe statusof the internal battery.
The battery charge statusis shown graphically and in text asa percentage between 0 and 100%, together with
the battery voltage.
Configuration of sensors:
It allows to check which sensors are installed on the instrument, and in which position they are installed. The
instrument automatically detects whether a sensor hasbeen either added or removed. The screen page allows
whether to accept the new configuration orignore the change performed.
Sensor diagnostics:
This feature displays useful information about the status as well as about the calibration of the internal
electrochemical sensors. Through this screen the user can access the data that fully identify the sensor, such
as: sensor type, serial number, manufacturing and calibration dates. In addition to this are also shown the
current valuesgenerated by the sensors thus allowing for a quicktroubleshooting in case of issues referable to
the sensors.
Gas path check
Tests the tightness of the gasprobe pneumaticpath.
Memories diagnostics:
At instrument turn on the firmware performs a full checkon the physical efficiency of all types of HW memories
installed on the instrument, aswell ason the integrity of the data stored into them. Any issue is evidenced in the
screen 'Memories Diagnostics'. Should this happen it is advisable to turn the instrument off and then on again.
In case the problem is permanent or frequently recurring, the user should contact the Service Center reporting
the error code shown by the instrument.
Info service:
This submenu contains details regarding the nearest Service Center to be contacted in the event of instrument
fault or ordinary maintenance. The instrument model, serial number and firmware version are also displayed,
thusallowing for a quickproduct identification.
External probe:
Showsusefull information about the probe connected to connector OFig. 2.2 on page 8.
The Flow Chart in the following page showshow to browse through the Info Menu screens.
4.8 Info Menu
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4.8.1Flow Chart - Info Menu
Activates the Info Menu. To return to the previous screen,
press .
►Battery status
Sensors Config.
Sensors diagnostic
Gas Path Check
Memories diagnostic
▼
INFO MATION
Bat: 91 ٪
Vbat:7.82 V
BATTE Y STATUS
Battery status
►Sensors Config.
Sensors diagnostic
Gas Path Check
Memories diagnostic
▼
INFO MATION
Battery status
Sensors Config.
►Sensors diagnostic
Gas Path Check
Memories diagnostic
▼
INFO MATION
►1:O 2 ok
2:CO ok
3:NO ok
SENSO DIAGNOSTIC
1:O 2 ok
►2:CO ok
3:NO ok
SENSO DIAGNOSTIC
1:O 2 ok
2:CO ok
►3:NO ok
SENSO DIAGNOSTIC
The battery symbol filling up means that battery charging is
ongoing.
This screen page shows, for each position, the following
messages (example referredto thesensor in position 2):
CO Sensor configured OK
□→CO Sensor missing or non communicating
CO→□ New sensor detected
CO Sensor detected in a wrong position
SENSO S TYPE
QUIT
1 3
2
O 2 NO
CO
Use arrows to scroll the parameters of each selected
cell. Here below are the data which can be displayed
through the sensors troubleshooting menu:
Type: Type of sensor
Revision: Sensor revision index
Date code: Production batch
Gas: Gas measured
Serial: Sensor serial number
Manufacturing date: Production date
Calibration date: Calibration date
Is: Sensor Is current
Ia: Sensor Ia current
Furthermore, under sensor troubleshooting mode, the
instrument can display the status of each single cell (here is
an example) visualized after the visualization of the
measured gas:
Ok: No problem detected
missing The sensor has not been detected
data err Sensor memory data error
Unknown The instrument FW needs to be
updated
pos err Sensor installed in the wrong
position
cal err Calibration error
curr err Currents out of range
non config This sensor is not to be used
because it has not been accepted in
the page 'type of sensor'.
Analysis config.
Instrument config.
►Information
CONFIG/INFO
►Analysis config.
Instrument config.
Information
CONFIG/INFO
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▲
Sensors Config.
Sensors diagnostic
Gas Path Check
Memories diagnostic
►Info Service
▼
INFO MATION
E Instruments
Tel.[phone]
Fax.[phone]
900
SN:000001 Ver:1.00
PN:000000
INFO SE VICE
Probe SN --------
EXTE NAL P OBE
▲
Sensors diagnostic
Gas Path Check
Memories diagnostic
Info Service
►External pobe
INFO MATION
Battery status
Sensors Config.
Sensors diagnostic
►Gas Path Check
Memories diagnostic
▼
INFO MATION
Connect to port P-
Apply cap to probe
Press OK to start
GAS PATH CHECK
Battery status
Sensors Config.
Sensors diagnostic
Gas Path Check
►Memories diagnostic
▼
INFO MATION
Memories ok
Calibration ok
MEMO IES DIAGNOSTIC
Connect to port P-
Apply cap to probe
Press OK to start
Please wait ...
GAS PATH CHECK
Connect to port P-
Apply cap to probe
Press OK to start
esult: leak
GAS PATH CHECK
Connect the flue gas sampling probe and filter unit assembly to the
instrument;
Fully insert the black rubber cap on the gas probe tip, as shown in the
following picture:
Black rubber cap

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4.9 Analysis configuration menu
Through thismenu the user can configure the available parametersfor a proper combustion analysis.
Fuel:
Letsthe user select the type of fuel to be used during analysis. This data can be changed either from this menu
or during the analysisitself.
Measurement units:
Through this submenu the user can modify the unitsof measurement for all the analysisparameters, depending
on how theyare used.
O2 Reference:
In this mode the user can set the oxygen percentage level that pollutant emission values are corrected to for
that given O2 reference level.
Automatic analysis:
The user can set analysis mode to eithermanual or automatic.
In manual mode the user performs the three necessary analysis operations manually. In automatic mode the
cycle duration for each reading must also be set - in this case the instrument will conduct each analysis in the
specified time.
Printing may also be manual orautomatic. If “auto” printing is selected, the instrument will automaticallyprint the
analysisreportin a predetermined format at the end of the automaticanalysis.
Condensation
The burner efficiency figure when condensation takes place is influenced by atmospheric pressure and humidity
of the combustion air.
As the atmospheric pressure is hardly precisely known, the operator isasked to enter a related parameter, i.e.
the altitude of the place above the sea level, from which the pressure isthen derived once the dependency from
atmospheric conditions is neglected. In calculations the value of 101325 Pa is assumed as atmospheric
pressure at sea level.
Further the air relative humidity input is allowed, being this calculated at the combustion air temperature as
measured from the instrument; in case thisvalue isunknow the operatorisrecommended to enter 50% for this
value.
NOx/NO Factor
NOx/NO: all the nitrogen oxideswhich are present in the flue emissions (Nitrogen oxide = NO)
In the combustion processes, it isfound out that the NO
2 percentage contained in the flue gas are typicallynot
far from very low values (3%); hence it ispossible to obtain the NOx value by a simple calculation without using
a direct measurement with a further NO 2 sensor.
The NO 2 percentage value contained in the fumescan be however set at a value other than 3% (default value).
Alarms:
This submenu allows the user to set and memorise 5 alarms, defining the monitored parameter for each, the
alarm threshold and relative unit of measurement and whetherit isa lowor high-level alarm.
Low-level alarms are triggered when the reading drops below the defined threshold, whereas high-level alarms
are triggered when the reading risesabove the defined threshold.
When an alarm threshold is crossed, the instrument emits an intermittent audible alarm besides activating a
visible alarm wherein the background of the name of the relative reading will start flashing in the analysis
screen.
When the CO and NO concentration thresholds are crossed, besides activating the audible and visible alarms,
the COand NO solenoid valvesmayalso be set to intervene and thereby interrupt sample flow.
If the instrument is not fitted with a solenoid valve, the sample pump will in any case be stopped.
Autozero/Pump:
Thissubmenu is used to set the duration of the analyzerauto-calibration cycle. It may also be used to switch off
or switch on the sample pump temporarily. The sample pump cannot be switched off if the auto-calibration cycle
isunder way.
Operator:
The name of the operator conducting the analysismay be set or modified through this submenu. A maximum of
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