horiba Checker CC-100E User manual

Operating instructions
Converter Checker CC-100E
1.0 • 22.02.2021 •

HORIBA Table of contents
NOx Converter Checker CC-100E iii
Table of contents
1
General notes4
1.1
Address of the manufacturer4
1.2
Warranty and liability4
1.3
Trademark4
1.4
Applied EU directives and standards5
1.5
Intended use5
2
Security6
2.1
Spellings used6
2.2
General safety instructions6
3
Device overview9
3.1
Scope of delivery9
3.2
Labelling9
3.3
Description9
3.4
Unit views10
4
Installation and commissioning12
4.1
Before installation12
4.2
Environmental conditions13
4.3
Installation13
5
Operation14
5.1
Operation15
5.2
Relationship between ozone generation andNOxconcentration18
6
Maintenance19
6.1
Safety instructions for maintenance19
6.2
Maintenance plan19
6.3
Troubleshooting19
6.4
Spare parts20
7
Decommissioning21
8
Disposal22
9
Appendix22
9.1
Technical data22
9.2
Flow chart24

General notes
HORIBA
4/ 24 NOx Converter Checker CC-
100E
1 General information
Copyright© 2021 HORIBA Europe GmbH, all rights reserved.
This manual describes the operation of the NOx Converter Checker CC-100E (with integrated ozone
generator), which can be used to check the efficiency of NOx-to-NO converters used in gas analysers
during emission measurements or for process gas analysis.
Be sure to read this manual before using the product to ensure proper and safe operation of the unit.
Keep the manual in a safe place so that it is always available when needed.
Product specifications and the appearance and contents of this manual are subject to change without
notice.
All procedures and illustrations described in this manual refer to a unit with specific features. Please note
that your unit may differ. If you have any questions, please contact us.
1.1 Address of the manufacturer
HORIBA Europe GmbHHans-Mess-Straße
661440 Oberursel / Germany
Phone: [phone]Fax:
[phone]E-mail
:
[e-mail]: www.horiba.com
1.2 Warranty and liability
The appliance is supplied by HORIBA with a warranty for a period of one (1) year.
In case of malfunction or damage within this year attributable to HORIBA, please contact HORIBA.
The warranty does not cover the following situations:
– Any malfunction resulting from improper operation.
– Any malfunction due to modifications or repairs not having been carried out or authorised by HORIBA.
– Any malfunction due to the use of the unit in an unsuitable environment.
– Any malfunction resulting from failure to observe the instructions in this operating manual.
– Any malfunction resulting from use of the appliance that does not comply with the instructions in this
manual.
– Any disruption resulting from natural disasters, accidents or breakdowns in which HORIBA is not
involved.
– Any malfunction due to the unit falling down.
– Signs of use such as rust etc. that are due to corrosion.
– consumables and the replacement of wear parts.
HORIBA is not liable for any damage caused by any malfunction of this product, any deletion of data, or any
other use of this product.
1.3 Trademarks
In general, company and brand names are either registered trademarks or trademarks of the respective
companies.

HORIBA General notes
NOx Converter Checker CC-100E 5/ 24
1.4 Applied EU directives and standards
This appliance complies with the following directives and standards:
Directive 2014/35/EU of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of the laws of Member States relating to the making available
on the market of electrical equipment designed for use within certain voltage
limits (Low Voltage Directive)
Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of the laws of the Member States relating to electromagnetic
compatibility (EMC Directive)
EN 61010-1:2011-07 Safety requirements for electrical equipment for measurement, control, and
laboratory use - Part 1: General requirements
EN 61326-1:2013-07 Electrical equipment for measurement, control and laboratory use - EMC
requirements - Part 1: General requirements - Part 1: General requirements
1.5 Intended use
HORIBA's CC-100E is used to check the efficiency of the conversion of NOx to NO, as is common in NOx
analysers in flue gas analysis or process gas measurement. By means of ozone production through high-
voltage discharge and mixing with externally supplied nitrogen monoxide (NO), exact NO2 concentrations
are generated in a short reaction time.

Security HORIBA
6/ 24 NOx Converter Checker CC-100E
2 Safety
2.1 Spellings used
Warnings used in these operating instructions consist of a signal word, a warning, mandatory or instruction
symbol, the type of hazard incl. consequences and the instructions for avoiding it.
indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or property damage.
indicates
important information about the product or actions that must be observed for
the correct functioning of the unit.
The following symbols are used in these operating instructions and to identify hazardous points on the
system:
Symbol
Meaning
Warning of a general danger
Warning of electrical voltage
Hot surface warning
General note
2.2 General safety instructions
Target group
These instructions are intended for skilled personnel who are familiar with the general hazards involved in
the installation, maintenance and operation of equipment in commercial or industrial environments.
Before installation and first commissioning, the personnel must obtain knowledge of the intended use of
the system by carefully reading these operating instructions.
– Operation - instructed competent personnel with required expertise
– Maintenance - qualified personnel with required knowledge, electrician
The warnings must be observed.

HORIBA
Security
NOx Converter Checker CC-100E 7/ 24
Electrical safety
DANGER
Electrical voltage
Danger of electric shock
 There are parts in the unit that are under dangerous voltage
a) The unit may only be opened by instructed, skilled personnel.
b) Disconnect the unit from the mains at all poles when carrying out maintenance
work on electrical components. To do this, pull out the mains plug. Simply
switching off the unit at the mains switch is not sufficient!
c) Secure the unit against unintentional restart.
d)
Work on the opened device when it is live may only be carried out by a specialist
who is familiar with the associated dangers.
Switch off in an emergency
WARNING
Emergency
 Uncontrollable operation of the appliance, occurrence of fire and smoke.
a) Switch off the unit and disconnect the mains plug.
b)
Close the valves on the gas cylinders or the external feeds.
Hazardous substances
WARNING
Toxic gases
 The unit handles toxic gases. Uncontrolled leakage of these gases can cause a
serious accident such as poisoning.
a) Connect the system according to this manual.
b) Use the specified connections as well as hoses and pipes and connect them
gas-tight.
c) Check that the applied gas pressure corresponds to the nominal value.
d)
Ensure that your working environment is properly ventilated.
CAUTION
Handling auxiliary materials and consumables
 Auxiliary materials and consumables may contain substances that are
hazardous to health or the environment.
a) Follow the instructions for action written in the safety data sheets of the
auxiliary materials and consumables.
b)
Wear your personal protective equipment if necessary.

Security HORIBA
8/ 24 NOx Converter Checker CC-100E
The following safety instructions are on the unit:
Reverse side:

HORIBA Device overview
NOx Converter Checker CC-100E 9/ 24
3 Unit overview
3.1 Scope of delivery
Designation
Quantity
NOx Converter Checker CC-100E
1 piece
Operating instructions
1 piece
Mains connection cable 230V
1 piece
3.2 Labelling
Fig. 1: Example of a type plate
The nameplate of the CC-100E is located on the back above the O2 inlet.
3.3 Description
The HORIBA Converter Checker CC-100E is a compact device for checking the reliability of gas analysers
for determining the NOx content in exhaust gases. For this purpose, the device generates ozone from an
oxygen-saturated atmosphere in a high-voltage unit, mixes the ozone with externally supplied NO and
produces a gas mixture with a precise NO2 concentration. The CC-100E is optimised for high stability and
short reaction times.
The operating principle of the NOx Converter-Checker CC-100E is based on gas phase titration (GPT). Gas
phase titration generally refers to any titration carried out in the gas phase. More specifically, it is a method
for determining reactive fractions in the gas phase by reacting with the excess of another gas that serves
as the titrant. In our case, the gaseous analyte is ozone, which can be "titrated" with nitric oxide according
to the following reaction
O3 + NO → O2 + NO2.
The unknown NO concentration can then be determined from measuring the concentration of the reaction
products.
Compared to simple spectrophotometry, gas phase titration has two advantages:
The measurement is not dependent on the path length of the gas path, as the same gas path is used for
both the measurement of the excess titrant and the measurement of the product.
The measurement also does not depend on the linear change in absorbance as a function of the
concentration of the gas to be analysed (Beer-Lambert law). Therefore, the method is particularly suitable
for such samples whose components interfere at similar wavelengths as the analysis gas.

Device overview HORIBA
10/ 24 NOx Converter Checker CC-100E
3.4 Unit views
Front view
Fig. 2: Front view
Position
Designation
1
ON/OFF switch
2
Touch screen for operation
3
USB 1 (not in use)
4
USB 2 (service interface for updating the firmware)
Rear view
Fig. 3: Rear view
Position
Designation
1
Oxygen inlet for ozone generation (inlet valve 1)
2
Nitrogen inlet as reference (inlet valve 2)
3
NO Calibration gas inlet (inlet valve 3)
4
Connection to the gas inlet of the analyser
5
Mains connection (Power)
6
RS232 interface
7
Bypass

HORIBA Device overview
NOx Converter Checker CC-100E 11/ 24
Interior view
Fig. 4: Interior view
Position
Designation
1
Inlet valve 1; oxygen inlet
2
Inlet valve 2; nitrogen inlet
3
Inlet valve 3; Calibration gas (NO) inlet
4
Output to the analyser
5
Mains connection
6
RS232 interface
7
Bypass
8
Power supply unit
9
Mixing area
10
Pressure regulator 2
11
Capillary line 2
12
Pressure regulator 1
13
Capillary line 1
14
Ozone generator

Installation and commissioning HORIBA
12/ 24 NOx Converter Checker CC-100E
4 Installation and commissioning
4.1 Before installation
Be sure to observe the following instructions before installation and commissioning:
NOTE
Installation
Installation must only be carried out by qualified personnel.
a) Follow all instructions in this manual.
b) Modifications to the unit are prohibited.
c)
Operate the unit only within the specified limits.
WARNING
Transport damage
Inspect the unit carefully for damage before operation. Safe operation is not
possible,
- if there is visible damage to the unit,
- if the unit no longer works correctly or
- After storage under damaging conditions
If one of these points applies, you must put the unit out of operation and secure it
against unintentional operation.
DANGER
Electrical voltage
Improper connection may result in electric shock or fire.
a) Make sure that the supply voltage corresponds to the specifications on the type
plate.
b)
Only connect the unit with the mains cable supplied. Do not use the mains cable
for other devices.
c) Do not open the unit! There are high-voltage components in the unit.
d)
Only connect the unit to an earthed socket.
WARNING
Potentially hazardous gases
Hazardous gases are passed through the appliance. There is a risk of poisoning
and/or suffocation if the gas is not connected properly.
a) Make sure that the operating pressure complies with the specifications.
b) Use only high purity gas.
c) Ensure that the work area is well ventilated and that exhaust fumes are safely
discharged.
d) Only use the specified connectors and lines and connect them gas-tight without
leaks.

HORIBA Installation and commissioning
NOx Converter Checker CC-100E 13/ 24
4.2 Environmental conditions
The unit is designed for the following environmental conditions.
– Overvoltage category: II
– Pollution degree: 2
– EMC: EN61326-1: 2013-07 Class A, Industrial
– Mains connection: AC 90 V to 240 V, 50/60 Hz
– Gas pressure: 20 kPa (200 mbar)
– Operating temperature: 5 °C to 35 °C
– Rel. humidity: < 80 %, non-condensing
– No direct exposure to heat and sunlight
4.3 Installation
WARNING
Hot surfaces on the appliance, risk of burns
 During operation, the surface of the appliance becomes hot.
a) Do not touch the surface during operation.
b)
Allow the unit to cool down before starting installation or maintenance work.
Connect
Fig. 5: Rear view
Place the unit on a level, stable surface.
1. Connect the gas supply lines (1 to 3).
2. Connect the bypass line (7) to a venting system.
3. Connect the "Analyser" output (4) of the CC-100E to the gas input of your analyser.
4. Make sure that all screw connections and lines are connected gas-tight before using the system for the
first time.
5. Set the correct inlet pressure according to the specification.
6. Connect the mains cable.
7. Switch on the unit.
8. The HORIBA start screen appears.
9. Operate the function via touch screen.

Operation HORIBA
14/ 24 NOx Converter Checker CC-100E
5 Operation
Overview of the test procedure:
Prepare the converter as described in the chapter "Installation" and allow the downstream analyser to
warm up.
NOTE
Preparation and settings
 Prepare the following:
Use an ozone number of 5 or more.
Make sure that the flow rate in the analyser does not fluctuate during the test.
Do not change the flow rate during the test.
Prepare a data entry sheet (see example below).
On the CC-100E
At the analyser
Status
Reading log
Select the operating
mode of the
analyser
Select the NO mode
Press the UP key
once
The N2 gas flows
into the analyser.
Step "Z" (zero
calibration of the
analyser)
Perform a zero
calibration after the
reading has become
stable.
Press the UP key
once
The NO gas flows
into the analyser.
Step "A" (range
calibration of the
analyser)
Perform the range
calibration after the
reading has become
stable.
Reading (A)
Press the UP key
once
The NO and O2 gas
flows into the
analyser
Step (a)
Reading (a)
Press the UP key
once
The O3 gas flows
into the analyser
Step (b) Set the measured
value (ozone) to 10%
to 20% of the
measuring range.
NO2 is produced,
which decreases the
NO value
Reading (b)
Press the UP key
once
Step (c) Changing the mode
from NO to NOx
Reading (c)

HORIBA Operation
NOx Converter Checker CC-100E 15/ 24
On the CC-100E
At the analyser
Status
Reading log
Press the UP key
once
The O3 gas stops,
NO and O2 flow into
the analyser.
Step (d)
Reading (d)
Press the UP key
once
O2 delivery is
stopped, only NO
flows into the
analyser.
Step (B)
Reading (B)
Press the UP key
once
The N2 gas flows
into the analyser.
Step (Z) The step ends
automatically about
60 seconds later.
End
Tip: To scroll back through the steps, press the DOWN button each time.
Data entry form
The efficiency of the converter is calculated as follows:
Efficiency of the converter =
Test sheet: Converter efficiency: Analyser no., XXXXXXX
Date Auditor Efficiency
(in %)
Reading
Reading
before
and after
the check
(a) (b) (c) (d) (A) (B)

Operation HORIBA
16/ 24 NOx Converter Checker CC-100E
5.1 Operation
Switch on
After switching on the CC-100E, the main screen appears:
Fig. 6: Main screen
The main screen schematically represents the gas flow through the unit. The components are controlled by
tapping on the corresponding symbol.
Control valves, supply oxygen
Tap the "SV" icons to open or close the inlet valves. A selection window with a yellow background appears:
Fig. 7: Open or close inlet valves
Open the corresponding valve with "Open". The colour of the valve and the gas path changes from blue
(valve closed) to yellow (valve open).
Close the corresponding valve with "Close".

HORIBA Operation
NOx Converter Checker CC-100E 17/ 24
Set ozone concentration and start ozone generator
Tap the "OGU" symbol. The window for setting the ozone concentration appears
Fig. 8: Ozone generation
Set the "counts" using the 100s / 10s / 1s key and the "Up" and "Down" keys. Switch the generator on with
the "On" key.
You can then work through the test sequence with the "Up" and "Down" buttons.
The set "counts" are displayed in the main screen.
NOTE
Relationship between counts and NO concentration
The value for "counts" should be 10 times the NO concentration in ppm.
Example:
For an NO concentration of 100 ppm, "counts" must be set to 1000
Supply external gas
To supply N2 (SV2) or NO (SV3) externally, open the respective inlet valve as described above.
Fig. 9: Opening the valves
NOTE
Supply external gas
The inlet valves SV2 and SV3 are interlocked. Only either N2 or NO can be supplied.

Operation HORIBA
18/ 24 NOx Converter Checker CC-100E
Switch off gas supply
1. Stop the ozone production by pressing the "OGU" button and then "OFF".
2. Close the SV3 valve and stop the NO supply.
3. Start a flushing process with nitrogen for at least one minute. To do this, open valve SV2 for the N2
supply.
4. Close the SV1 valve and stop the O2 supply.
5. Close the SV2 valve and finish the flushing process.
6. Switch off the unit at the mains switch.
5.2 Relationship between ozone generation and NOx concentration

HORIBA Maintenance
NOx Converter Checker CC-100E 19/ 24
6 Maintenance
6.1 Safety instructions for maintenance
DANGER
Electrical voltage
Danger of electric shock
 There are parts in the unit that are under dangerous voltage
a) The unit may only be opened by instructed, skilled personnel.
b) Disconnect the unit from the mains at all poles when carrying out maintenance
work on electrical components. To do this, pull out the mains plug. Simply
switching off the unit at the mains switch is not sufficient!
c) Secure the unit against unintentional restart.
d) Work on the op
ened device when it is live may only be carried out by a specialist
who is familiar with the associated dangers.
6.2 Maintenance plan
The specified intervals for checking the following components are recommendations. More frequent
replacement may be necessary depending on the application, installation environment, purity of gases used
and other factors.
Component
Exchange interval
Description
Action
Ozone generator
1 to 3 years
Check for contamination
Exchange by HORIBA
Inlet valves SV1 to SV3
In case of defect
Check for contamination
Exchange by HORIBA
Pressure regulator
In case of defect
Check for contamination
Exchange by HORIBA
Capillaries
In case of defect
Check for contamination
Exchange by HORIBA
6.3 Troubleshooting and fault rectification
Situation
Possible causes
Remedial action
The CC-100E cannot be switched
on.
– The main power line is
switched off.
Check the main power line.
–
The supply voltage is wrong.
Connect the correct voltage
–
The power switch is OFF.
Turn on the power switch.
– The fuse has blown.
Replace the fuse with a fuse of the
same type.
The display does not change. – NO gas is not supplied.
Open the inlet valve for the NO gas
supply.
Check the gas pressure
– A leak has occurred. Check the gas lines and screw
connections. Connect the gas lines
properly.
– The gas line is not connected
properly.
Connect the piping properly.
The display is unstable. – The pressure produced is out
of specification.
Regulate the pressure to a value in
the specified range.

Maintenance HORIBA
20/ 24 NOx Converter Checker CC-100E
Situation
Possible causes
Remedial action
– The pressure generated at the
outlet is out of specification.
Regulate the pressure to a value in
the specified range.
The reaction speed is slow. – The residual pressure of the
gas is too low.
Regulate the pressure to a value in
the specified range. Connect a new
bottle if necessary.
– The inlet pressure is too low. Regulate the pressure to a value in
the specified range.
– A leak has occurred. Check the gas lines and screw
connections. Connect the gas lines
properly.
–
The flow is too low
Ensure a sufficient flow rate.
6.4 Spare parts
The following spare parts can be obtained from the manufacturer:
Spare part
Type
Item no.
Inlet valve 1 (oxygen)
Type 6011
1000067176
Inlet valve 2 (nitrogen)
Type 127
1000067178
Inlet valve 3 (nitrogen oxide)
Type 127
1000067178
Pressure regulator 1
UA13-S202-AV
3011014227
Pressure regulator 2
UA13-L202-SV
3011021069
Capillary 1
SA-101
3014056923
Capillary 2
SA-102-J
3014056400
Ozone generator
OGU
3014061759

HORIBA Decommissioning
NOx Converter Checker CC-100E 21/ 24
7 Decommissioning
To put the unit out of operation, carry out the following steps:
Switch off gas supply
1. Stop the ozone production by pressing the "OGU" button and then "OFF".
2. Close the SV3 valve and stop the NO supply.
3. Start a flushing process with nitrogen for at least one minute. To do this, open valve SV2 for the N2
supply.
4. Close the SV1 valve and stop the O2 supply.
5. Close the SV2 valve and finish the flushing process.
6. Switch off the unit at the mains switch.
Store unit
1. Remove the mains cable.
2. Remove the gas connections.
3. It is best to store the unit in its original packaging in a dry and dust-free place.