Extech Instruments CO80 User manual

CO80
Combustion Gas Analyzer

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Table of Contents
1. Introduction 4
2. Instrument Overview 5
2.1. Standard Items 5
2.2 Options 5
2.2.1. Leak Detection Capability 5
2.2.2. Air/Liquid/Surface Probe 5
2.3 Front View 6
2.4 Back View 7
2.5 Keypad 8
2.6 Display 9
2.7. Inlet Ports 10
2.8 Filter/Water Trap 11
2.9 Thermocouple Socket (Type-K) 12
2.10 Infrared Window 13
3. Setting Up 13
3.1 Power 13
3.2 Probe Selection 14
4. Taking Combustion Readings 15
4.1 Summary Procedure 15
4.2 Switching On 15
4.3. Scale Selection 15
4.3.1. Fuel Selection 16
4.3.2. Temperature Selection 16
4.3.3 Printer/PC Selection 17
4.3.4 Pressure Settings 17
4.5 Flue Readings 18
4.6. Reports 19
4.6.1 Saving a Report 19
4.6.2 Printing the Last Saved Report 20
4.6.3 Printing Any Saved Report 21
4.6.4. Deleting the Last Report 21
4.6.5. Deleting All Reports 21
4.6.6. Sending a Report 21
4.7. Switching Off 22
4.7.1 In Normal Mode 22
4.7.2 Power Off In High CO Levels 22
4.7.3 Power Off During CO Room Test 23

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5. Other Functions 24
5.1 Taking Pressure Readings 24
5.1.1. Standard Pressure Readings 25
5.1.2. Tightness Test 26
5.1.3. Pressure and Temperature Readings 29
5.2 Taking Efficiency Readings 30
5.3 Clock 31
5.4 Header Settings 31
5.4.1. Changing the Header Characters 31
5.4.2. Setting your Security Code 32
5.4.3. Changing a Security Coded Header 33
5.5 Taking Carbon Monoxide Readings 33
5.5.1 CO Spot Leak Detection 33
5.5.2 CO Room Test Mode 33
5.5.3 Printing the Last CO Report 35
5.5.4 Deleting the Last CO Report 35
5.5.5 To Print all CO reports 35
5.5.6. To Delete all CO Room Test Reports 36
5.6 Differential Temperature Measurement 36
5.6.1 Differential Thermometer Set up 36
5.7 Gas Leak Detection 38
6. Calibration and Service 39
7. Guarantee 39
Appendix A Specifications 40
1. Instrument 40
2. Probes 40
3. Options 40
5. Gases 41
6. Draught/Pressure Measurement 41
Appendix B Header Character Set 42
Appendix C Trouble Shooting Guide 43
Appendix D Communicating with a PC 45
Appendix E Setting Up the Printer 47

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1. Introduction
Thank you for your purchase of the Extech CO80. This instrument has
been specifically developed to provide the many functions required by the
modern boiler service engineer and to assist with compliance to existing
and future legislation.
The CO80 now offers five tools in one instrument:
1. Flue Gas Combustion Analyser.
2. Differential Manometer.
3. Differential Thermometer.
4. Real time Carbon Monoxide Gas Leak Detector.
5. Gas Leak Detector.
In addition, there is a user selectable choice of fuels, temperature and
pressure measurements.
This manual will take you through the functions and operations of the
CO80 that will give you many years of reliable service.
Please also contact our technical support team at
[phone] x 200 or [email protected] for additional information.
WARNING
This instrument is not designed to be used in continuous operation, nor is it to be
used as a safety alarm.
It is designed to assist the heating engineer in diagnosing the correct installation or
maintenance of heating appliances.
Full visual inspections of those appliances will be necessary, and other procedures
should be adopted as appropriate.

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2. Instrument Overview
2.1. Standard Items
Your CO80 kit comes supplied with the following items as standard:
a) CO80 flue gas analyser
b) Sample/thermocouple probe, with 2.5 meters of tubing and cable
c) Filter/water trap
d) Battery charger
e) 2 off silicon tubing for pressure reading
f) Soft carrying case
2.2 Options
2.2.1. Leak Detection Capability
This sensor option is fitted inside the instrument, enabling the CO80 to
detect flammable gas leaks.
Once the gas leak screen has been cleared in order to view other screens
and measurements, the thirty second purge period will be to be
reactivated in order to perform other gas leak checks.
2.2.2. Air/Liquid/Surface Probe
See Appendix A for specification details, Display 4 in Section 2.6 to see
readings, and Sections 2.9 and 3.2 for connection.
Additional options include a protective rubber boot, an infra red printer, a
hard carry case and an IrDA converter.

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2.3 Front View
Charger Socket
Exhaust Cover
Infrared Window
Gas & Pressure
Inlet Ports Thermocouple
Sockets
Keypad
LCD Display

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2.4 Back View
Exhaust
Cover
Infrared
Window
Gas & Pressure
Inlet Ports
Thermocouple
Sockets
Barcode
Label
Calibration
Label

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2.5 Keypad
Turns the instrument ON or OFF. Note that
the instrument will automatically switch off if
not used for a period of 15 minutes (see 4.2
for additional information
)
The straightforward
membrane keypad
comprises 6 keys,
where a single touch
will have the following
functions:
Used to reset the pressure to ambient levels.
Activates the Tightness Test
Turns the back light on/off and records the
pressure for the soundness test and the
temperature in the pressure test
Scrolls through up to 8 displays, depending
on options taken (see 2.6).
Logs and prints sets of readings, or logs and
downloads up to 50 sets of combustion analysis and
25 CO room test readings to a PC (see 4.6).
Displays the clock and is used to scroll through
saved reports– keeping this held down for 2
seconds activates the soundness test.

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2.6 Display
There are eight standard displays on the CO80, although several of the
displays have multiple functions and options. These depend upon the
probes connected and menu selected.
Display 1
CO in ppm, carbon dioxide in
%, and ratio of the 2 gases –
use this screen to provide an
instant “health check” of the
boiler.
Display 4
Displays the positive and negative
pressure (selected by connecting to
the appropriate inlet).
Display 4 options also include a
tightness test count-up timer and
logging of the temperature during
pressure test, dependent on mode
and connections (see Section 5).
Display 2
Oxygen, excess air and
combustion efficiency all
in % - use this screen to
display how efficiently the
boiler is working.
Display 3
Displays oxygen in %, and
carbon monoxide in ppm – use
this screen to identify any CO
gas leaks and concentration
levels.

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2.6 Display (continued)
Display 6
Time (24 hours), day, month
and year.
Display 8
Provides temperature
information. The outlet (flue)
temperature is displayed on the
top of the screen and the inlet at
the bottom, with the difference
between the two displayed in
the middle.
Display 7
Provides information on the CO
levels for the room test.
Pressing & holding the “Log”
starts the test and the display
alternates between the elapsed
time period in minutes and the
maximum CO in ppm for that
minute.
Display 5
This is displayed only when
the leak sensor option has
been specified. It indicates
approximate concentrations
of flammable gas (See
2.2.1).

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2.7. Inlet Ports
There is one gas sample port and two pressure ports on the base of the
instrument, to which 5 mm ID silicone tubing can be connected by push
fitting. The use of these ports is also identified on the information label on
the base of the instrument.
2.8 Filter/Water Trap
Tubing to CO80
Screw Cap Filter
Housing Top
Filter Housing
Tubing from Probe
Inner Filter
Direction of
Sample Flow -
Displayed on
Housing
Pressure (-ve) Pressure (+ve)
Gas Sample
Port

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2.8 Filter/Water Trap (continued)
The combined filter/water trap is used in-line between the probe and the
instrument. To change the filter, unscrew the filter-housing cap, remove
the old filter and replace. Emptying the water trap is advisable whenever
water is seen to be accumulating.
Filters should be changed every two months under normal operation or
sooner if there is clear indication of contamination. Should the filters
become soaked in water, these can be reused if left to dry fully. Filters
must be used at all times – failure to do so shall invalidate any warranty.
2.9 Thermocouple Socket (Type-K)
WARNING
There is only one correct way around to connect the thermocouple.
Forcing the connector into the socket the wrong way around may result in
damage to the instrument and will invalidate any warranty.
The CO80 accepts a
standard type-K
thermocouple connection
for both Inlet and Outlet.
+
_
Outlet
(flue)
Inlet

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2.10 Infrared Window
The infrared window allows communication with a compatible infrared
printer, or to a PC with a suitable infrared port. The instrument window is
located on the left-hand side of the instrument next to the gas exhaust.
To operate effectively, there must be a clear line of sight between the
instrument infrared window, and the PC or printer infrared window. The
two windows should be not more than three feet apart when in PC mode
and 12” when in printer mode.
3. Setting Up
3.1 Power
The unit may be powered in 2 ways.
(a) By using the integral rechargeable Ni-MH batteries. Overnight
charging using the BGS101 charger will give a minimum of 6
hours continuous use (excluding leak detection option). The unit
does not have to be switched on to charge the batteries, but if it is,
after 15 minutes the instrument will automatically switch off whilst
charging continues.
(b) Direct from the mains using the BGS101 battery charger.
Following use after a full charge, when there is approximately 30
minutes operational life remaining, a battery symbol will appear in
the bottom right hand corner of the display:
When on charge, the above symbol will flash only if the instrument
has been switched on then off with the charger connected.

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3.2 Probe Selection
The instrument is equipped with a standard sample and temperature
probe, enabling the instrument to measure and display combustion
efficiency. It is of stainless steel construction, and is supplied with 8 feet of
sample tubing and cable.
The pistol grip probe is connected to the gas sample port and
thermocouple socket, as shown, for combustion monitoring.
The sample probe assembly includes the inline filter (see section 2.8) and
this must be used in the vertical position.
The additional air, surface and liquid temperature probe, if used, is
connected into the thermocouple socket marked outlet (flue) at the base of
the unit.
For pressure measurement, the ports are to be connected using the
supplied 5 mm internal diameter silicon tubing to the positive and/or
negative ports as required.
+
_
Gas Sample
Tube
Thermocouple
Lead

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4. Taking Combustion Readings
4.1 Summary Procedure
1. Ensure batteries are charged, or instrument is connected to a
mains supply (see 3.1).
2. Ensure water trap is empty (see 2.8).
3. Switch on, select fuel, temperature and pressure scales,
printer/PC selection if modification is required (see 4.3).
4. Take flue readings (see 4.5).
5. Save, print, review or send data (see 4.6).
6. Empty water trap.
7. Switch off (see 4.7).
4.2 Switching On
Attach the appropriate probe and the filter/water trap, ensuring that the
assembly is fitted in-line in the right direction (see 2.8).
Important: The instrument should be calibrated in outside (clean)
ambient air.
Press and hold “On/Off” to activate the unit. The pump will be heard
working, and a countdown of 30 seconds will begin. “Purge” will be
displayed in the bottom left hand corner. Ensure the gas exhaust outlet is
not obstructed.
During this countdown, the oxygen cell will be calibrated to ambient air
conditions. At the end of the countdown sequence, the following will be
displayed:
4.3. Scale Selection
Only during the 30 second purge period on power-up can the user alter
the fuel, pressure, temperature and communication settings. Should the
user wish to use another setting during operation, the power must be
recycled and the changes made during the second purge on power-up
cycle.
The CO and CO2readings
should read zero in outside
ambient air. “rnG” (range) is
displayed against “Ratio” if
the CO2reading is less than
0.5%.

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Should no alternations occur during the power-up purge period, the last
used settings shall automatically be reapplied.
4.3.1. Fuel Selection
During the power-up purge period, the last fuel selected will appear at the
top of the display. To change the fuel press and hold down the “Scroll”
button, which scrolls through the following 5 available fuels as follows:
Natural Gas
LPG
Light Oil
Heavy Oil
Fuel 1
Release the “Scroll” button when the fuel to be selected is displayed. By
default “Fuel 1” is factory set for measurement when coal is used as the
boiler fuel.
4.3.2. Temperature Selection
During the power-up purge period, the press and hold “Light” to display
the current temperature scale setting. Either “C” or “F” will be displayed.
Press and hold “Light” until the required temperature scale is display.
Allow the purge period to end to retain settings.

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4.3.3 IR Output Mode Selection
The output mode for the infrared window can be selected for two formats:
PC = for a personal computer and Extech IR printers.
HP = for Hewlett Packard IR printers.
During the countdown sequence, press and hold the “Log” to display
either PC or HP alternating on the screen. Release the “Log” button when
the appropriate output mode to be selected is displayed. MOST
APPLICATIONS WILL USE THE PC MODE.
4.3.4 Pressure Settings
To review or alter the pressure scale during the power-up purge period,
press and hold down the “Pressure” button, which scrolls through the
following 5 available fuels as follows:
bAR (mbar)
PSI (pounds per square inch)
nnG (mm of water column)
inG (inches of water column)
Release the “Pressure” button when the pressure to be selected is
displayed and allow the purge period to end in order to save this setting.

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4.5 Flue Readings
After competing steps 4.1 to 4.3.4, the instrument should now be ready to
take combustion readings.
WARNING
Ensure that the combined filter/water trap hangs in a vertical position
whilst readings are being taken, and particularly if water is visibly present.
Failure to comply with this may result in damage to the instrument
4.5 Flue Readings (Cont.)
The time the gas sample takes to pass over the gas sensors from the flue
is approximately 10 seconds, and a further period of time should be
allowed for the readings to stabilise (approximately an additional 5
seconds).
WARNING
If the CO concentration exceeds a level of 2,000 ppm, a continuous series
of ‘alarm beeps’ will be heard. The probe should be immediately
withdrawn from the flue, and the probe detached from the instrument. The
instrument should be run in outside ambient air until CO and CO2readings
return to zero.

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4.6. Reports
Once a stable set of readings is displayed on the screen of the CO80, the
next step is to save (or log) this data to the internal memory in the
instrument for future output to a printer, or download to a PC or laptop
computer. (See appendix D for details on how to communicate with a PC.)
The CO80 saves 50 combustion reports and 25 CO room test reports.
When the memory is full and a new reading is taken, the oldest report is
overwritten. By pressing the “LOG” button, the following will be displayed
in the bottom left hand corner of the screen:
4.6.1 Saving a Report
Keeping hold of the “Log” key for two seconds will save the last report
once a “beep” is heard. With “Save” flashing on the display, press and
hold down the “Log” button for approximately 2 seconds - the instrument
will save a full set of readings to the next available memory location. The
CO80 will “beep” to confirm that the report has been saved.

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4.6.2 Printing the Last Saved Report
See Appendix D for
instructions on configuring
the printer.
To print the last report, press
the “Log” button followed by
the “Scroll” button. The
“Print” display at the bottom
of the screen will now flash.
Press and hold the “Log”
key for two seconds until a
“beep” is heard and the last
report will be printed.
The printer must be turned
on with its IR port pointing at
the IR port of the CO80 (see
2.10 for additional
information) in order for the
printing to commence.
Note: It is possible to review
a report on the display by
printing without linking to the
printer or PC.
The printout has provision for
writing in customer and
appliance details.
The header can easily be
configured to provide the
name and contact details of
the boiler service engineer
(see section 5.4).
A typical set of readings is
indicated on the right:
-------------------------------------------
EXTECH INSTRUMENTS.
781-890-7440
-------------------------------------------
Combustion Appliance
Test Report
-------------------------------------------
Customer
-------------------------------------------
-------------------------------------------
-------------------------------------------
Appliance
-------------------------------------------
Ref.
-------------------------------------------
Flue Gases
-----------------------------------------
Log…………….…………………2
Date…………..14:53,29/09/2002
Fuel: NATURAL GAS
O2 ( %)...…………………….20.9
CO (ppm)…..………………….11
CO2 (%)………..……………..3.1
Ratio (CO/CO2)……...…..0.0003
Temp (C) ………..…………..263
Efficiency (%)………….……70.1
Excess Air (%)………………..37
-------------------------------------------