E Instruments E8500 Plus Installation instructions manual

INSTRUCTION & OPERATIONS
MANUAL
E8500 Plus
PORTABLE INDUSTRIAL
INTEGRATED EMISSIONS SYSTEM
COMBUSTION GAS ANALYZER
E Instruments International LLC
402 Middletown Bl d, Suite 216
Langhorne, PA, USA 19047
Phone [phone]
Fax [phone]
www.E-Inst.com

E8500 Instruction & Operations Manual version 1.017
Page 2 of 49
ABLE OF CON EN S
LIST OF ABBREVIATIONS ............................................................................................. 3
ANALYZER OPTIONS .................................................................................................... 4
CHAPTER 1
FUNDAMENTALS ........................................................................................................... 5
CHAPTER 2
THE INSTRUMENT KEYBOARD .................................................................................. 11
CHAPTER 3
BASIC INSTRUMENT OPERATION ............................................................................. 12
CHAPTER 4
POWER REQUIREMENTS ........................................................................................... 14
CHAPTER 5 - TECHNICAL
SAMPLE FLOW & SAMPLE CONDITIONING SYSTEM .............................................. 15
CHAPTER 6 - TECHNICAL
SENSORS ..................................................................................................................... 19
CHAPTER 7
ANALYZER SETUP ...................................................................................................... 24
CHAPTER 8
INTERNAL DATA STORAGE ....................................................................................... 29
CHAPTER 9
WIRELESS REMOTE PRINTER ................................................................................... 31
CHAPTER 10
CALIBRATION .............................................................................................................. 33
CHAPTER 11
COMMUNICATIONS ..................................................................................................... 39
CHAPTER 12
MAINTENANCE………………………………………………………………………………..40
APPENDIX A
MODEL E8500 – SPECIFICATIONS ............................................................................ 44
APPENDIX B
FIRMWARE PROGRAMMING ...................................................................................... 48
APPENDIX C
REPLACEMENT PARTS .............................................................................................. 49

E8500 Instruction & Operations Manual version 1.017
Page 3 of 49
LIST OF ABBREVIATIONS
PARAMETERS
AIR Excess air
CO Carbon monoxide (a toxic gas)
CO
2
Carbon dioxide – NDIR measurement OR calculated from O
2
DF Draft/Pressure
DU Y Duty cycle is a power setting gi en in percent
EFF Combustion efficiency (for boilers and furnaces, does not apply to
engines)
HC Hydrocarbons (NDIR) measurement – (HC is same as CxHy)
H
2
S Hydrogen Sulfide (a toxic gas)
N.A. Parameter not a ailable
NO Nitric oxide (a toxic gas)
NO
2
Nitrogen dioxide (a toxic gas)
NO
X
Oxides of nitrogen (a toxic mixture of NO & NO
2
gases)
O
2
REF Oxygen reference basis for correction of toxic gas concentrations
SO
2
Sulfur dioxide (a toxic gas)
a Ambient (room) temperature
p Preheated Air temperature
g Gas temperature
HERMAL EFF Engine thermal efficiency (heat loss method of calculation, not the
same as combustion efficiency)
VEL Stack Gas Velocity
VOC Volatile Organic Compounds
UNITS
CFM Cubic feet per minute, ( olumetric stack gas flow-rate)
CMM Cubic meters per minute, ( olumetric stack gas flow-rate)
FPS Feet per second (stack gas elocity measurement)
MPS Meters per second (stack gas elocity measurement)
#/H Pounds (of pollutant) per hour (mass emissions)
/D Tons per day (mass emissions)
PPM Parts (of pollutant) per million ( olume basis-dry)
MGM Milligrams (of pollutant) per cubic meter
GBH Grams (of pollutant) per (engine) brake horsepower-hour.
#/B Pounds (of pollutant) per million BTU (of fuel).
"WC Inches of water (draft/pressure measurement)
mmWC Millimeters of water (draft/pressure measurement)
kPa KiloPascals (draft/pressure measurement)
mbar Millibars (draft/pressure measurement)
% Percent by olume, dry-basis
in2 Square inches (cross sectional area of stack)

E8500 Instruction & Operations Manual version 1.017
Page 4 of 49
ANALYZER OPTIONS
The E INSTRUMENTS Model 8500 Plus is an extremely ersatile emissions
measurement system that meets practically all emissions requirements. It has been
designed as a modular system, permitting the installation, in the field, of most of the
arious a ailable options. This manual describes the complete instrument equipped with
all the options.
E8500 Plus standard capabilities include 12”/300mm stainless steel probe
(1470ºF/800ºC max.) with dual hose sampling line, ambient and stack temperature
measurements, O2, CO, & NO gas sensors, dilution pump and electronic al e for dual
range CO and purging capability, draft & differential pressure measurements, 2000
internal storage tags, wireless remote printer (optional), Bluetooth wireless PC
communications, EGAS Windows
TM
software, custom fuel programming option, and
extensi e help screens. The a ailable options are separated into two categories:
1. ANALYZER SENSORS
 Nitrogen dioxide (NO
2
) sensor - 5-Series electrochemical sensor
 Sulfur dioxide (SO
2
) sensor – 5-Series electrochemical sensor
 Hydrogen sulfide (H
2
S) sensor – 4-Series electrochemical sensor
 Carbon dioxide (CO
2
) – non-dispersi e infrared (NDIR) sensor
 Hydrocarbon (CxHy or HC) – non-dispersi e infrared (NDIR) sensor
 High Carbon monoxide (CO) – non-dispersi e infrared (NDIR) sensor
 Volatile Organic Compounds (VOC) – PID (photo-ionization) sensor
2. SAMPLE EXTRACTION & TRANSPORT SYSTEMS
A. Stainless steel probe with dual hose sample line (1470ºF/800ºC max.) in probe
lengths of 12”/300mm (standard) or 30”/750mm (optional)
B. Inconel probe (2200ºF/1200ºC max.) with 10’/3m sample line in arious probe
lengths

E8500 Instruction & Operations Manual version 1.017
Page 5 of 49
CHAPTER 1
FUNDAMENTALS
The E INSTRUMENTS Model E8500 Plus Integrated Emissions System is a portable
state of the art analyzer designed to measure, record and remotely transmit combustion
parameters used for the following tasks:
A. To measure the oxide of nitrogen emissions from stationary combustion sources
by means of electrochemical sensors in accordance with the EPA Pro isional
Reference Method (EMTIC CTM-022, CTM-030, & CTM-034) for portable NOx
analyzers.
B. To measure the emissions of carbon monoxide, sulfur dioxide and oxygen sources
from stationary and mobile combustion sources by means of electrochemical
sensors.
C. To use NDIR technology to measure simultaneously, gaseous hydrocarbons as
methane, carbon monoxide, and carbon dioxide. he Model 8500 Meets EPA’s
Reference Method 25B Appendix A 40CFR60 “Determination of otal
Gaseous Organic Concentration Using a Nondispersive Infrared Analyzer”.
D. To compute the emission rates in lbs/million BTU or lbs/hour (mass emissions) for
carbon monoxide, NOX and sulfur dioxide, and in tons/day for carbon dioxide
according to the EPA’s 40CFR75 regulations for continuous emissions monitoring.
E. To measure the stack gas elocity and olumetric flow rate and emission rates
according to the EPA Method 2, or Method 2C, Appendix A of 40CFR60.
F. To assist the operator of a combustion source with the task of optimizing its
efficiency, performance, and fuel sa ings.
G. To be used as a management tool to assist the plant manager with keeping
records and controlling costs.
The E INSTRUMENTS E8500 Plus also uses the best a ailable compact conditioning
system technology with a proprietary battery operated thermoelectric chiller for accurate
transport of the sample gas to the instrument. It also uses sophisticated electronics and
programming design for increased accuracy and flexibility. It measures 3 temperatures
and 9 different stack gases. It calculates efficiency of combustion as well as excess air
and carbon dioxide. In addition, it can compute emissions in fi e different systems of

E8500 Instruction & Operations Manual version 1.017
Page 6 of 49
units (PPM, milligrams/m
3
, lbs/MMBTU, grams/brake horsepower-hour, and lbs/hour). It
stores, prints and graphs data. It communicates with a ariety of other computers,
tablets, and other Windows compatible de ices located nearby using Bluetooth wireless
technology. It has a library of 15 fuels. It is designed to operate on its internal
rechargeable battery pack as well as AC power.
The basic operation is as follows:
You insert the extraction probe in the stack of an operating combustion source such as
a boiler, furnace, or combustion engine. A pump located inside the instrument draws a
small sample of the stack gas. The gas sensors analyze the contents of the stack gas
and its temperature and calculate & display the results. In addition, an optional Pitot
tube measures the elocity of the stack gases, which allows for mass emissions
calculations. The results can also be stored in memory, printed out, or sent remotely to
a computer using the Bluetooth wireless communications. The source operator can
make the required adjustments on the combustion source based on the analysis of the
stack conditions to optimize performance of the combustion source.
A. UNPACKING THE INSTRUMENT
E ery E INSTRUMENTS Model E8500 Plus includes as standard equipment:
• Emissions Analyzer Model E8500 Plus with integrated chiller conditioning
system and automatic condensate drain
• Stack sampling probe that includes the probe shaft, sample line/hose, and
thermocouple cable/connector
• Battery charger / AC adaptor for the analyzer
• EGAS
TM
Software for Windows
TM
on USB Flash Dri e
• Bluetooth module (internal)
• USB Communications Cable
• Protecti e carrying case with shoulder strap
• Calibration certificate
• Instruction manual on USB Flash Dri e
B. E8500 STARTING INSTRUCTIONS
1. Make sure the instrument is in a clean-air, room-temperature en ironment and
turn it on by pressing the POWER button on the keypad.
2. Press the OK button to begin an autozero countdown. Once the display shows
AUTOZERO COMPLETE, you are ready to use the instrument for your
measurements. You can also initiate the autozero the analyzer by first pressing
the CALIB button. The cursor will rest on the first line of the display, which states

E8500 Instruction & Operations Manual version 1.017
Page 7 of 49
Zero All Sensors. Press OK. The display will automatically switch to the
MEASURE mode and the last line will execute a countdown. At the end of the
countdown you are ready to use the instrument.
3. If, at the end of the autozero countdown, the display shows an error message for
a particular sensor, see the troubleshooting table in section D of this chapter. The
instrument will measure correctly all sensors that do not show an error message.
4. With the analyzer in its case, connect the probe to the unit. One hose with the
quick disconnect fitting connects to the “Sample In” port, and the other hose
connects to the “+” pressure port. The thermocouple connector plugs into the
“Stack” temperature connector. For the most accurate draft measurements,
another autozero calibration should be done (through the CALIBRATION button
menu) after the probe & hoses are fully connected to the analyzer but before the
probe is inserted into the stack.
5. The instrument can ha e up to six electrochemical gas sensors, one PID sensor,
and three infrared (NDIR) gas sensors. The E8500 Plus has three temperature
sensors total.
6. All sensor readings are single range readings with ranges listed in Appendix A.
The CO reading is an exception. If the CO concentration exceeds the “Dilute CO”
threshold that can be adjusted in the SETUP menu, a CO dilution takes place
automatically to increase the CO dilution measurement range to as high as
20,000 ppm. If the measured CO concentration exceeds the upper end of the set
dilution range, then a CO purge mode is initiated. If any of the ranges are
exceeded for the other sensors the corresponding parameter will read OVER on
the display. In that case, it is strongly recommended to withdraw the probe from
the stack immediately and let the analyzer run with the pump on in a clean air
en ironment to pre ent sensor saturation.
NO E: For CO measurements greater than 20,000 ppm, the optional
CO NDIR sensor can measure up to 15% CO.
C. SAFETY GUIDELINES & ADVICE
Most stack gases are hot, full of moisture, corrosi e, and laden with soot particles.
To make sure that your instrument will gi e you a long time of trouble-free performance,
please obser e the following recommendations.
1. Follow the instructions in the E8500 Plus manual.
2. Ne er use the instrument without the disposable fiber soot line filter or the
condensation disk filter, which are located inside the analyzer. Operating the

E8500 Instruction & Operations Manual version 1.017
Page 8 of 49
instrument without the filters will put the analyzer at high risk to damage the
pump and sensors. These filters should be replaced as needed.
3. The built-in thermoelectric chiller remo es moisture from the stack gas as it
enters the analyzer, and the automatic condensate drain pump sends
accumulate condensate out the bottom of the analyzer. It is best to let the
E8500 Plus run with the main gas pump on for at least a few minutes after
measuring is done to let all of the condensate automatically drain out of the
analyzer and to also fully purge the stack gases out of the unit.
4. Do not expose the probe tip to open flame.
5. Do not rest the stack probe’s sampling line on a hot boiler surface.
6. Allow the probe tip to cool off and the instrument to aspirate clean air before
packing the probe.
7. It is strongly recommended to use single span calibration gas mixtures,
preferably with balance nitrogen when calibrating the sensors for the most
precise calibrations.
8. Keep the analyzer upright in the protecti e carrying case with the LCD display
facing up for best operations of the unit.
WARNING: Never lay the E8500 Plus on its side with the display screen
& keypad upside down.
9. If the analyzer enclosure if e er unscrewed and taken apart, be careful when
pulling the top piece off the bottom piece because there is a ground wire
connecting the two main pieces. Do not o er-tighten the screws that hold the
two main enclosure pieces together.

E8500 Instruction & Operations Manual version 1.017
Page 9 of 49
D. AUTOZERO ERRORS & BASIC TROUBLESHOOTING
AU OZERO ERRORS
Channel Possible Causes Resolution
(Electrochemical
sensors)
CO
NO
NO
2
SO
2
H
2
S
O
2
Sensor has been
recently exposed to
gas and has not yet
returned to zero.
Purge for 10 minutes,
monitor sensor oltage,
and re-zero.
Battery was dead,
sensor has
destabilized.
Charge battery, wait up
to 24 hours for sensors
to stabilize, and re-zero.
Sensor cell is dead. Call for a replacement.
T Stack
Thermocouple is not
connected
Check electrical
connections running to
the probe
Thermocouple was
hot
Probe tip should be cool
Stack Draft Probe not connected Draft oltage will be
high. Connect probe and
re-zero or ignore draft
readings.
Filters are dirty Draft oltage will be low.
Check filters
Infrared CO-CO
2
-HC 00 No response from
infrared system
Autozero period must be
at least 60 seconds.
Zero the instrument
again.
Infrared CO-CO
2
-HC XX Infrared system is
reporting error code
XX
Infrared system may
need maintenance.
Velocity Velocity probe is not
connected
Check probe and
connections.
Flow (low) Filters are clogged
and/or wet
Replace filters as
needed
Flow (high) Gas exhaust at
bottom of unit blocked
Unblock exhaust and
check all hoses

E8500 Instruction & Operations Manual version 1.017
Page 10 of 49
ROUBLESHOO ING
Symptoms Possible Causes Resolution
Analyzer will not turn
on. (Screen is off)
Battery is dead. Plug in the charger.
Analyzer should turn on.
Battery is not
charging.
Check the charger and
jack. Check the case for
excessi e heat.
Internal initialization
problem.
Reset the analyzer.
Analyzer turns on but
screen is blue or
faded.
Internal initialization
problem.
Reset the analyzer.
Analyzer is
o erheating.
Unplug charger.
Check fan.
Turn on & off to reinitialize.
Analyzer locks up or
will not turn off
properly.
Internal initialization
or power problem.
Reset the analyzer.
Display Screen
shows “Connect
Charger”
Battery is completely
discharged. No
power to analyzer.
Connect charger to
analyzer. Confirm charger
pro ides 12V output.
“Low Flow” on display
screen
Filters are clogged
and/or wet
Check & replace filters
inside analyzer as needed
Probe/Hoses are
blocked or pinched
Check probe & hoses
“High Flow” on
display screen
Gas exhaust at
bottom of analyzer is
blocked
Check exhaust hose to
make sure it is not blocked
or clogged
NOTE: The reset button is located on the bottom of the analyzer
approximately 1.5” (4 cm) from one of the four black feet as shown in the
photo below. You will need a pen tip or other small object to press the
reset button. Make sure the charger is disconnected from the analyzer
when pushing the reset button.

E8500 Instruction & Operations Manual version 1.017
Page 11 of 49
CHAPTER 2
THE INSTRUMENT KEYBOARD
A brief explanation of the instrument’s buttons is as follows:
CALIB
Controls calibration settings and zeroing of the analyzer’s sensors.
SE UP
Controls all customization parameters (such as measurement units)
for the analyzer
MEASURE
Displays the analyzer’s currently measured data in either of two fonts:
A. Small fonts (all data displayed simultaneously plus range indicated,
battery condition and time)
B. Large fonts (four data parameters displayed simultaneously)
POWER
Turns analyzer and conditioning system on and off
S ORE
Controls operation of the analyzer’s internal data storage
P
RIN
Executes print commands for the analyzer’s remote printer
OK
Used with the direction keys to change a setting or na igate the
menus
▲
Mo es the cursor up or increments the entry marked by the cursor
▼
Mo es the cursor down or decrements the entry marked by the cursor
◄
Mo es the cursor to the left
►
Mo es the cursor to the right

E8500 Instruction & Operations Manual version 1.017
Page 12 of 49
CHAPTER 3
BASIC INSTRUMENT OPERATION
It is possible to master the basic operation of the instrument in a few minutes by
following the procedure outlined below. Please refer to the other sections of this manual
for a description of the more ad anced features.
The E8500 Plus emissions analyzer consists of the following three major components:
1. The probe sampling line, whose function is to extract the sample, sense
the stack temperature and depending on the option measure the stack gas
elocity
2. The conditioning system is located inside the analyzer and consists of the
thermoelectric chiller, automatic condensate draining system, and filters
3. The main section of the analyzer that houses all the gas sensors, battery
pack, and PC board
To operate the instrument, follow the steps outlined below.
1. Turn the E8500 Plus analyzer on. The instrument pump will immediately turn on
and the E INSTRUMENTS logo will appear. Press OK to run the autozero cycle.
2. Attach the probe and sampling line that is supplied with your analyzer. One hose
connects to the Sample In connector, and the other hose connects to the positi e
(+) pressure connector. The thermocouple connector from the stack gas
sampling probe should be connected to the Temperature 1 thermocouple
connector on the analyzer.
3. If you are using the analyzer for the first time,
press the SE UP key to set the appropriate
parameters (i.e. fuel, units, etc.) for your
application. See Chapter 7 for an explanation of
each parameter. A table of the SETUP display is
shown here.
OCT 1 ‘15 12:45:00
Fuel: NATURL GAS
Tem erature Units: F
Measure Units: PPM
Pressure Units: inWC
O2 Reference: TRUE
Pum s: OFF
Dilution Duty: 100%
Water Drain: 25min
Chiller Duty: 75%
Dilute CO: 5000 PPM
Use CO-IR: 7000 PPM
Thermal Eff: 0.30
Dis lay Contrast: 24
Baudrate: 9.6 kb s
Version: 1.00
Battery: x.xx V

E8500 Instruction & Operations Manual version 1.017
Page 13 of 49
4. Press the MEASURE key and check the unit’s battery condition.
The MEASURE key toggles between a small font and a
large font screen. Select the small font screen.
The battery icon is displayed in the middle of the bottom
line of the display. Its condition is marked by the shaded
fraction of the icon. If the unit is powered by the battery
charger a small “plug” icon will replace the battery icon.
NO E: When connecting the battery charger to the
analyzer make sure that the “plug” icon appears on the
MEASURE screen. This ensures a proper power
connection and charging of the batteries.
5. After making sure that the analyzer is drawing clean air at room temperature,
press the CALIB key. The cursor (re erse color) will point to the line:
Zero All Sensors
Press the OK key to execute an autozero cycle of all the sensors.
6. At the end of the autozero period, all sensors should indicate zero reading with
the exception of the oxygen sensor, which should read 20.9% (the concentration
of ambient dry air), and the stack temperature, which should correspond
approximately to the room temperature.
7. Insert the analyzer’s probe into the stack or engine exhaust. Use the MEASURE
key to read the stack parameters.
8. To obtain a printout of the data displayed, press the PRIN key. The cursor
(re erse color) will point to:
Print Test Record
Press the OK key to execute a printout on the E8500 Plus’s remote printer.
9. Measured data can be stored in the analyzer’s internal memory. Please refer to
Chapter 8 for more details about data storage.
10. When you are finished with your measurements, withdraw the probe from the
stack, allow the analyzer to draw clean ambient air for se eral minutes and for
the probe to cool down, before packing the analyzer in its carrying case.
EFF:xx.x% CO: xxxx PPM
Tg: xxxx°F NOx:xxxx PPM
O 2 : xx.x% NO: xxxx PPM
HC:xx.xx % NO 2 : xxx PPM
CO 2 :xx.x% SO 2 : xxx PPM
DFT:xx.x” H 2 S: xxx PPM
_____________________
LOW RANGE 12:45:00
NOTE: Depending on the
options enabled for your
analyzer some of the entries in
one or more of the displays
shown above will be blank if
that option is not available.

E8500 Instruction & Operations Manual version 1.017
Page 14 of 49
CHAPTER 4
POWER REQUIREMENTS
The E8500 Plus can run off of AC power or the internal rechargeable battery pack. It is
recommended to run the E8500 Plus off AC power as often as possible for maximum
operating time and optimal chiller performance.
Power is supplied by a rechargeable battery pack. A 110 – 240 Volt AC charger ha ing
a 12 Volt DC / 2.5A output is supplied with the instrument. The battery charger will fully
charge the battery pack in a minimum of six hours.
A fully charged battery pack will supply power to the analyzer for approximately 3 to 5
hours of continuous operation depending on the unit’s options and utilization.
A new E8500 Plus should be charged with the unit powered off for 12 to 24 hours. It is
not suggested to charge the unit for more than 24 hours when powered off.
If the battery pack is fully discharged, charge the analyzer while off for at least 1 to 2
hours before turning the analyzer on.
You can check the condition of the batteries at any time:
1. By pressing the MEASURE key, (small font screen) and obser ing the battery icon,
located at the bottom of the display, in the middle, or
2. By pressing the SE UP key and obser ing the actual battery oltage, displayed on
the last line. When the unit is operating on battery power, the oltage displayed will ary
from an initial 8.0 to 8.4 olts (fully charged) dropping slowly to approximately 7.25 olts
(batteries nearly empty). When the battery oltage drops to 7.3 olts a “low battery”
warning will appear on the display. Within a few minutes later the instrument will
automatically turn off, to preser e the remaining battery power for the sensor bias
oltages.

E8500 Instruction & Operations Manual version 1.017
Page 15 of 49
CHAPTER 5 - TECHNICAL
SAMPLE FLOW & SAMPLE CONDITIONING SYSTEM
PART A. THE EXTRACTION PROBE AND SAMPLING LINE
A number of different types of probes are a ailable depending on the application
requirements. The probe consists of the extraction probe, the sampling line and the
stack thermocouple.
1. Medium temperature probe and sampling line. This standard probe is
suitable for temperatures up to 800ºC/1470ºF.
2. High temperature probe and sampling line. This probe uses an inconel
extraction probe suitable for temperatures up to 1200ºC/2200ºF and ery
low NO
2
and SO
2
loss sampling line suitable for emissions measurements.
Different extraction probe and sampling line lengths are a ailable on
request.
The end of the probe’s sampling line connects to the SAMPLE IN quick disconnect
connector of the analyzer and the thermocouple connector connects to
TEMPERATURE STACK input of the analyzer.
Pitot tube – This optional part consists of stainless steel tubing with the tips open and
bent at a certain angle according to the EPA specifications of 40CFR60 Appendix A,
Method 2 for measuring stack gas elocities. The S-Type Pitot tube must always be
oriented with the open tips parallel to the direction of the stack gas flow. Care must be
taken to keep the tubes from getting clogged by soot particles. The end of the Pitot tube
assembly is connected by means of two flexible hoses to a ery accurate pressure
transducer located inside the analyzer.
PART B. THE SAMPLE CONDITIONING SYSTEM
The purpose of the sample conditioning system is to remo e the excess condensation
from the extracted stack gas sample and also to remo e soot particles. The exhaust
sample contains typically between 5% and 20% of water apor, most of which will
condense in the probe and sample line.

E8500 Instruction & Operations Manual version 1.017
Page 16 of 49
NO
2
and SO
2
are gases that are highly soluble in water. To pre ent significant loss of
NO
2
and SO
2
during transport of the sample from the probe to the analyzer, the
following conditions must be satisfied:
1. Rapid sample transport. This is accomplished by maintaining a high flow rate
using a relati ely small diameter sampling line.
2. Preferably use of a sample line made from a highly hydrophobic material, such
as Teflon, Viton, or stainless steel.
3. Minimum contact of the gas sample with the water collection mechanism and
also no additional condensation to occur following the thermoelectric chiller. This
is accomplished by using a specially designed Peltier cooled manifold to
separate the gas from the water.
Additionally, an optional SCU (Sample Conditioning Unit) shown in the photo below can
be used to dry the stack gas before it passes through the sample hose. The SCU is
recommended for applications of high moisture applications and/or when measuring
Low NOx or Low SO
2
.
SCU (Sample Conditioning Unit)
Condensate Catch Pot
(included
with the SCU) with manual drain
plug

E8500 Instruction & Operations Manual version 1.017
Page 17 of 49
The sample conditioning system located inside the analyzer as shown in the following
photo:
The following components are mounted on the conditioning system:
1. Thermoelectric chiller. The sample gas enters this aluminum manifold from
the front panel. The condensed water is remo ed and collects at the bottom.
The dry sample exits towards the filters. The manifold is cooled by the Peltier
element, powered by electrical pulses of user-settable duty cycle. By cooling
the chiller below ambient temperature, any further condensation in the
analyzer is pre ented.
The chiller will maintain the sample at a certain temperature below ambient
temperature to ensure that no further condensation takes place inside the
analyzer. You can control this temperature differential by adjusting the
CHILLER DUTY CYCLE, if necessary, as detailed below.
The duty cycle of the thermoelectric chiller is set at the factory to 75%. It
should not be adjusted unless when being used to measure a stack gas with
ery high water content. It can be adjusted as follows:
1) Press the SE UP key. The SE UP MENU will be displayed.
2) Press the UP/DOWN keys until the cursor points to COOLER DU Y.
3) Press the OK key.
4) Use the UP/DOWN keys to set the power duty cycle.
5) Press the OK key.
2. Water trap. The condensed water collects inside this water trap.
Thermocouple
Connectors
Line
Filter
Thermo-Electric
Chiller with Fan
Condensate
Water Trap
Condensate
Pump
Gas
Sampling
Pump
Damper

E8500 Instruction & Operations Manual version 1.017
Page 18 of 49
3. Condensate pump. This peristaltic pump operates automatically on a periodic
basis that can be set by the customer to remo e the condensed water from
the water trap and discharge it in the back of the instrument. The default
operation is 30 seconds on, 25 minutes off.
4. Line filter. The dried gas sample goes through a disposable fiber filter whose
function is to trap any soot particles from the sample. This filter must be
inspected often especially for oil or coal fired applications.
5. Condensation filter. The primary function of this 2 ¼” diameter filter is to
pre ent any residual condensation from reaching the sensors area. This
precaution is particularly important, especially if the analyzer is equipped with
an NDIR sensor bench.
6. Sample pump. This is a high quality diaphragm pump whose function is to
extract a sample from the stack. Its flow rate is adjustable and can be set by
instrument command (pump duty). Typical flow rates are 1.1 – 1.4 liters per
minute.
7. Damper. The last component is the conditioning system is a small damper
whose function is to smooth the flow pulsations generated by the sample
pump. The electrochemical sensors are diffusion type and their accuracy is
affected by significant flow pulsations.

E8500 Instruction & Operations Manual version 1.017
Page 19 of 49
CHAPTER 6 - TECHNICAL
SENSORS
The great ersatility of the Model 8500 Plus Emissions system is partly due to the large
number of sensors a ailable within a single analyzer.
These sensors are primarily gas sensors and can be grouped into three categories
based on their principle of operation:
1. Se en electrochemical gas sensors
2. Three NDIR (non-dispersi e infrared) gas sensors
3. One PID (photo-ionization) sensor
4. Non-gas sensors (temperature & draft/stack gas elocity) sensors
The figure below shows the location of the sensors on their housing:

E8500 Instruction & Operations Manual version 1.017
Page 20 of 49
1. ELECTROCHEMICAL SENSORS
All electrochemical sensors, except for the H
2
S sensor are of the 5 series type mounted
on bayonet style fittings for easy remo al.
The electrochemical sensors are described below following the order by which the gas
flows through the manifold.
A. Nitrogen dioxide sensor (NO
2
)
This is a three electrode sensor that responds to nitrogen dioxide gas. Nitrogen dioxide
is a “sticky” gas and this sensor’s response is usually the slowest of all sensors.
B. Sulfur dioxide sensor (SO
2
). It is a three electrode sensor that responds to sulfur
dioxide gas. It is equipped with an inboard filter to remo e interference from H
2
S gas.
C. Nitric oxide sensor (NO sensor)
This is also a three electrode sensor that responds to nitric oxide. It is equipped with an
inboard filter to remo e any interference from NO or SO
2
gases.
The nitric oxide sensor requires a constant bias- oltage for proper operation. This is
supplied by the analyzer’s battery. If the battery oltage drops below a certain alue the
analyzer will turn off automatically to maintain the sensor bias. If, howe er, the battery
oltage further drops to near zero, one must wait 24 hours after connecting the battery
charger, for the sensor bias to reco er.
D. Oxygen sensor (O
2
sensor)
This sensor measures the oxygen concentration in the sample. It is a two-electrode
electrochemical cell. It has a sil er cathode and a lead anode. Oxygen diffuses through
a tiny hole and reacts with the lead anode. The reaction produces an electric current.
The unit software linearizes the current s. oxygen response. The cell becomes
exhausted when all the lead is consumed.
E. Hydrogen sulfide sensor. (H
2
S)
This is a 4-series three-electrode micro sensor with low methanol interference. It
measures the concentration of hydrogen sulfide, which is a highly toxic gas. Special
precautions must be taken during calibration.
F. Carbon monoxide sensor and sensor assembly (CO)