Madur Sensonic 4000 User manual

Sensonic 4000 CONTENTS
1 CONTENTS
1 CONTENTS............................................................................................................................................
2 INTRODUCTION...................................................................................................................................
2.1 USE OF THIS OPERATING MANUAL............................................................................................
2.2 SYMBOLS USED..............................................................................................................................
3 MAINTENANCE....................................................................................................................................
3.1 Gas sensors.......................................................................................................................................
3.2 Gas sys em........................................................................................................................................
3.3 Ba ery..............................................................................................................................................
3.4 Service in ervals................................................................................................................................
3.5 Errors during opera ion....................................................................................................................
3.6 Swi ching off af er use.......................................................................................................................
4 GENERAL INFORMATION...................................................................................................................
5 CONSTRUCTION..................................................................................................................................
5.1 Elemen s of gas circui ......................................................................................................................
5.1.1 Gas probe wi h in-line fil er.........................................................................................................
5.1.2 Gas pump.....................................................................................................................................
5.1.3 Gas chamber................................................................................................................................
5.2 Measuremen sys em.........................................................................................................................
5.2.1 Gas sensors..................................................................................................................................
5.2.2 Ambien air empera ure sensor...................................................................................................
5.2.3 Flue gas empera ure sensor........................................................................................................
5.2.4 Gas chamber empera ure sensor................................................................................................
5.2.5 Differen ial pressure sensor.......................................................................................................
5.2.6 Analogue inpu s.........................................................................................................................
5.3 Da a inpu /ou pu sys ems...............................................................................................................
5.3.1 Keyboard...................................................................................................................................
5.3.2 Display.......................................................................................................................................
5.3.3 Prin er........................................................................................................................................
5.3.4 In erface RS 232C......................................................................................................................
5.4 Power supply..................................................................................................................................
6 OPERATION........................................................................................................................................
6.1 USE OF THE KEYBOARD.............................................................................................................
6.1.1 Descrip ion of he keys...............................................................................................................
6.1.2 Selec ing Menu Op ions.............................................................................................................
6.1.3 En ering Numbers......................................................................................................................
6.1.4 Edi ing Tex ................................................................................................................................
6.2 Basic opera ing ins ruc ions...........................................................................................................
6.2.1 Se ing-up he analyser..............................................................................................................
6.2.2 Swi ching on...............................................................................................................................
6.2.3 Swi ching off / S andby..............................................................................................................
6.2.4 Ini ial Calibra ion......................................................................................................................
6.2.5 Measuremen Parame ers..........................................................................................................
6.2.5.1 Fuel 19
6.2.5.2 Average Time.....................................................................................................................
6.2.5.3 Reference Oxygen parame er.............................................................................................
6.2.5.4 Boiler Parame er................................................................................................................
6.2.5.5 Con en of NO in NOx........................................................................................................
6.3 Displaying he measuremen resul s...............................................................................................
6.3.1 Curren Values...........................................................................................................................
6.3.2 Averaged Values.................................................................................................................
6.3.3 The Averaging Process..............................................................................................................
6.4 Pressure/Draf Measuremen s........................................................................................................
6.5 Soo (smoke) Con en s Measuremen ..............................................................................................
6.6 Graphic...........................................................................................................................................
40PLUS_E.DOC/06.97

CONTENTS Sensonic 4000
6.7 Flow measuremen ..........................................................................................................................
6.8 Op ions............................................................................................................................................
6.8.1 Device Info.................................................................................................................................
6.8.2 Sensors.......................................................................................................................................
6.8.2.1 Au o-Calibra ion O2..........................................................................................................
6.8.2.2 Analogue Inpu s.................................................................................................................
6.8.2.2.1 Gas empera ure sensor - TH GAS...........................................................................30
6.8.2.2.2 Ambien empera ure sensor - PT AMB....................................................................30
6.8.2.2.3 Ex ernal hermocouple- - T1 EXT and T2 EXT........................................................30
6.8.2.2.4 Ex ernal resis ance hermome er - T3 EXT and T4 EXT..........................................30
6.8.2.2.5 Ex ernal Vol age/Curren inpu s - U/I1 EXT and U/I2 EXT.....................................30
6.8.2.3 Sensor calibra ion..............................................................................................................
6.8.3 Device Se ings...........................................................................................................................
6.8.3.1 Backligh ............................................................................................................................
6.8.3.2 Con ras ..............................................................................................................................
6.8.3.3 Da e/Time...........................................................................................................................
6.8.3.4 Prin er................................................................................................................................
6.8.3.5 Language Version..............................................................................................................
6.8.3.6 Acous ic Alarm...................................................................................................................
6.8.3.7 Soo Tes .............................................................................................................................
6.8.3.8 S andard.............................................................................................................................
6.8.4 Service.......................................................................................................................................
6.8.4.1 Measured Values................................................................................................................
6.8.4.2 CONTROL LIST.................................................................................................................
6.8.4.3 madur Service.....................................................................................................................
6.9 S oring of Resul s............................................................................................................................
6.9.1 S oring measuremen repor s.....................................................................................................
6.9.1.1 Repor able........................................................................................................................
6.9.1.2 Header (No ice) edi ion......................................................................................................
6.9.1.3 Erasing Repor s..................................................................................................................
6.9.2 Con inuous s oring of resul s.....................................................................................................
6.9.2.1 Banks Table........................................................................................................................
6.9.2.2 Erasing Banks..........................................................................................................
6.10 Da a-Logger...................................................................................................................................
6.11 Prin er.............................................................................................................................................
6.11.1Prin ing he con en s of a screen...............................................................................................
6.11.2Prin ing of all resul s.................................................................................................................
7 BASIC PRINCIPLES OF CALCULATING RESULTS..........................................................................
7.1 Quan i ies ob ained from direc measuremen s (O2, CO, NO, SO2)...............................................
7.2 Calcula ing he concen ra ion of carbon dioxide............................................................................
7.3 Calcula ing he concen ra ion of ni rogen oxides NOx...................................................................
7.4 Concen ra ion of "undilu ed" carbon monoxide COundil...............................................................
7.5 Mass concen ra ions of gas componen s.........................................................................................
7.5.1 Absolu e mass concen ra ion of gas componen s.......................................................................
7.5.2 Mass concen ra ions rela ive o he concen ra ion of oxygen in combus ion gases...................
7.6 Calcula ing combus ion parame ers...............................................................................................
7.7 Fuel parame ers..............................................................................................................................
7.8 The influence of fuel parame ers on he accuracy of resul calcula ions........................................
8 BLOCK DIAGRAM..............................................................................................................................
9 MENU STRUCTURE...........................................................................................................................
9.1 S ruc ure of he main menu.............................................................................................................
9.2 S ruc ure of he menu STORE.........................................................................................................
9.3 S ruc ure of he menu DATA...........................................................................................................
2

Sensonic 4000 INTRODUCTION
2 INTRODUCTION
Congratulations on your purchase of the microprocessor-controlled flue gas analyser
Sensonic 4000
It is a high quality instrument produced using the latest technical discoveries. The Sensonic 4000 is
easy to use. You also have the possibility of using the extra capabilities of this analyser, of
examining measurement results, checking service intervals and many others. Please read the
operating manual carefully. It contains valuable tips and information for problem-free operation.
Regular maintenance will help to keep your analyser ready for use at all times.
2.1 USE OF THIS OPERATING MANUAL
Keep this manual with the analyser Sensonic 4000, and take it with you when carrying out measurements.
Here is a short description of the sections of this manual.
3 MAINTENANCE
This section contains important information designed to keep your analyser working and to save you time
and trouble.
4 GENERAL INFORMATION
This describes the most important characteristics of your new analyser.
CONSTRUCTION
A knowledge of the hardware of the analyser will help you to use the instrument correctly and to avoid
unnecessary down-time.
6 OPERATION
This section explains the use of the analyser with detailed descriptions of the various functions. It is
important to read the sections 6.1 and Błąd: Nie znaleziono źródła odwołania first. The other sections can
be read as and when required.
6.11 BASIC PRINCIPLES OF CALCULATING RESULTS
Here you will find all the necessary theory and formulas used in the calculations carried out by your
analyser
2.2 SYMBOLS USED
MENU
- press the key shown
 (5.6.1 Theme) - Further information to this theme is avai ab e in the operating manua
- ATTENTION important information
Information or instructions marked so can be skipped if not immediately needed.

MAINTENANCE Sensonic 4000
3 MAINTENANCE
3.1 Gas sensors
The following points are important for maximising the operational life of the cells and achieving
measurements without errors:
### do not exceed the rated concentration;
### all the gas cells may react unpredictably to the presence of substances which are not usually
found in flue gases. For this reason, the analyser may not be cleaned with chemical solvents. If
organic solvents enter the gas chamber, the cells may become unstable or even suffer
permanent damage;
### some cells require the presence of a bias voltage when not in use. Do not allow the battery to
become fully discharged;
### do not switch the analyser off before the system is purged of remaining flue gas;
### store the analyser in a cool place to reduce the ageing of the cells.
3.2 Gas system
The gas system of the analyser is protected by a double in-line filter. The elements should be changed when
necessary. Check the condensate traps regularly and empty them when needed.
3.3 Battery
The rechargeable battery used in the analyser is maintenance-free. An acoustic warning signal is given when
the voltage drops below 11 V. The Sensonic 4000 will switch off automatically if the voltage drops below
10.5 V. The analyser will operate for about 5 hours from the battery.
Some parts of the analyser draw current even when the device is switched off.
If the analyser is not being used then the battery should be charged fully at
least once a month.
3.4 Service intervals
The parameters of the electrochemical cells change with time, and therefore it is necessary to carry out a
service periodically. This service should include re-calibration of the gas sensors using test gases. The
recommended service interval is 800 operating hours or 6 months, whichever comes first. The analyser is
fitted with an operating hour counter and automatically shows when a service is necessary.
The operating time and the number of hours until the next service are shown in SERVICE/DEVICE INFO.
3. Errors during operation
The analyser checks all circuitry continuously. Should an error become evident, then this is signalled
acoustically and by the message "ERROR" on the screen. The error can be found shown on the screen
OPTIONS/SERVICE/CONTROL LIST.
3.6 Switching off after use
The operating life of the electrochemical cells is dependent on the usage of the instrument. The wear and
tear on the cells is greater when the cell is exposed to the gas for longer or the concentration is higher. The
gas cell is hence "used up" during measurements.
For this reason, the analyser should not be switched off until all the gas tubing has been completely
cleared of flue gases and the gas cells have been purged with fresh air for several minutes.
The Sensonic 4000 will not normally allow the instrument to be switched off if there are still traces of flue
gas in the system. The analyser will continue to operate until the signals from the gas cells are nearly zero.
This activity is shown by the message "VENTILATION REMOVE PROBE FROM FLUE".
4

Sensonic 4000 MAINTENANCE
The [OFF] key must be pressed twice to switch the instrument off completely. Pressing the key once will
put the analyser in the standby mode and the instrument will remain in this mode until it is activated again
by pressing "C" or switched off completely.
Certain conditions, such as strong electro-magnetic fields can cause the
analyser to become "hung-up". The only solution to this problem is to switch
the instrument off. It is, however, possible that the analyser will no longer
react to the keyboard and can not be switched off.
P r e s s i n g t h e [ O F F ] k e y f o r a p e r i o d o f a b o u t
t h r e e s e c o n d s w i l l a l w a y s s w i t c h t h e a n a l y s e r
o f f .

GENERAL INFORMATION Sensonic 4000
4 GENERAL INFORMATION
The Sensonic 4000 is a multi-functional flue gas analyser. Electrochemical sensors are used for the
measurement of gas concentration. The instrument can be fitted with between 2 and 6 of these sensors. All
analysers are fitted with O2and CO sensors, further gas cells must be chosen when the instrument is
ordered.
The following description is based on an analyser containing 3 cells, the third one being an NO sensor.
### Oxygen, O2
### Carbon monoxide CO
### Nitric oxide NO
### Carbon dioxide CO2
### Nitrogen oxides NOx
The first three gases ( O2, CO, NO ) are measured directly using the electrochemical cells. The remaining
components are calculated. The concentrations of oxygen and carbon dioxide are shown in percent. The
concentrations of the remaining gases is shown as follows:
### volume concentration in [ppm]
### absolute mass concentration in [mg/m3]
### mass concentration relative to the oxygen content in [mg/m3]
### mass concentration relative to the energy output in [mg/MJ]
In addition, the air inlet or ambient temperature and flue gas temperature are measured. Using the measured
temperatures, gas concentrations and the known fuel parameters the analyser calculates a variety of
combustion parameters such as Stack Loss - SL, Efficiency - , Excess Air - , Loss through Incomplete
Combustion - IL.
The Sensonic 4000 also measures differential pressure.. This can be used to measure the draught or
pressure in the flue gas channel and, using an appropriate Pitot tube, the flow velocity of the gases. The
instrument is also equipped for the soot test according to Bacharach.
The analyser is also fitted as a 3 channel data logger, capable of measuring a voltage or current channel
together with two temperatures using a variety of thermocouples and thermoresistors.
The instrument can be used at as broad range of ambient temperatures (0 - 50°C). It is fitted with a
rechargeable battery making it independent of the mains power supply.
Hence, the Sensonic 4000 is ideally suited for all those involved in the construction, maintenance and
adjusting of heating systems.
The keyboard of the instrument can be wiped clean if necessary.
The Sensonic 4000 is controlled by a microprocessor. The easy-to-read LCD display, the comprehensive
keyboard and the built-in printer allow the operator to communicate with the instrument easily and to
document the measurements on the spot. The EEPROM memory used in the Sensonic 4000 allows large
quantities of data to be stored without fear of data loss should the instrument be switched off or should the
battery be accidentally run down. The Sensonic 4000 comes complete with programmed data for the 16
most common fuels. A further 10 fuels can be programmed by the operator to cover all eventualities.
The RS232C interface fitted to the Sensonic 4000 allows all stored data to be read for later treatment or the
instrument can be used on-line with the computer.
6

Sensonic 4000 CONSTRUCTION
CONSTRUCTION
Picture (page 50) shows a block diagram of the Sensonic 4000.
Here is a description of the individual components.
.1 Elements of gas circuit
.1.1 Gas probe with in-line filter
The gas probe is used to extract the gases under investigation and to measure their temperature. The gas
probe consists of two parts, the probe pipe with thermocouple (1) and the probe holder (2).
Picture 1 Gas probe with in-line filter
The probe pipe is typically supplies in one of four standard lengths: 150 mm, 300 mm, 750 mm and 1500
mm. As standard a Ni-CrNi thermocouple is used. The probe pipe is fitted with an anchor cone to simplify
fixation in the flue gas channel.
The probe pipe is attached to the probe holder with a threaded connector.
The gas tubing in the Sensonic 4000 is protected from the dust and moisture present in the flue gases by a
filter (4). The filter elements (3) should be changed when dirty to ensure a free flow of gas. The condensate
should be removed from the condensate traps when necessary.
The plug (6) and hose end (5) are connected to the front plate of the analyser.
.1.2 Gas pump
The internal gas pump draws the gas into the Sensonic 4000 and passes it through the gas chambers. The
self-cleaning pump is a high quality item and is known to be extremely reliable.
The gas cells operate best with a flow rate of 90 l/h, which is set at the factory and compensates
automatically for flow restrictions or changes in battery voltage.
.1.3 Gas chamber
The gas chamber is fitted with between two and six gas sensors. Oxygen and carbon monoxide sensors are
fitted as standard equipment. The other cells are chosen when the instrument is ordered. The gas chamber of
the Sensonic 4000 system is characterised by minimal dead capacity, which leads to low inertia of the
analyser indications. In addition to the gas sensors, there is a temperature sensor placed in the chamber for
temperature compensation of the sensors.

CONSTRUCTION Sensonic 4000
.2 Measurement system
.2.1 Gas sensors
The oxygen concentration is measured using an electrochemical cell. The sensor signal is directly
proportional to the oxygen volume concentration. The oxygen sensor needs no calibration with standard
gases - it is fully calibrated during the initial calibration when a point corresponding with the contents of
oxygen in clean air (20.95%) is determined.
The toxic gases are also measured using electrochemical cells
Table 1 presents all the gas sensors available. Any of them can be used in Sensonic 4000 system.
To guarantee long-lasting, trouble-free function of electrochemical sensors the following points are
important:
### the stated maximum measuring range of the sensor should not be exceeded.
### all the gas sensors can react unpredictably to certain chemicals which are not typical for
combustion gas composition. For this reason, i t i s a b s o l u t e l y f o r b i d d e n t o
w a s h t h e p a r t s o f t h e g a s l i n e w i t h c h e m i c a l s o l v e n t s . The
vapours from such solvents can get inside the gas chamber and result in destabilisation or even
permanent damage of the gas sensors.
### the gas sensors are working even when the analyser is switched off - so the battery should never
be disconnected or completely discharged.
### the analyser should not be switched off before all the flue gases have been removed from the
analyser gas circuit.
### the sensor chamber must be kept dry.
### the switched off analyser should be kept in a cool place, which increases the lifetime of the gas
sensors.
.2.2 Ambient air temperature sensor
The ambient temperature is measured by the analyser for use in some of the calculations carried out, such as
Stack Loss. This can be carried out either by the temperature compensation sensor built into the plug of the
probe holder (INT) or the external connector. The temperature sensor is chosen under the suboption
OPTIONS / SENSORS / ANALOGUE INPUTS.
.2.3 Flue gas temperature sensor
Flue gas temperature sensor is situated in the gas probe pipe and plugged into PROBE socket on the front
panel of the analyser. This sensor is a NiCr-Ni thermocouple in the standard probe version. The range of
such a thermocouple is 50-800oC in the standard version (1100°C available optionally). A special gas probe
with PtRh-Pt thermocouple can also be used, with a range up to 1600oC. Proper flue gas temperature
measurement is the most important factor for correct calculation of the chimney loss and other heat
engineering results.
.2.4 Gas chamber temperature sensor
To compensate for temperature drift of the gas cells, the temperature of the gas chamber is constantly
monitored.
8

Sensonic 4000 CONSTRUCTION
.2. Differential pressure sensor
The Sensonic 4000 is fitted with a precise semiconductor differential pressure sensor. Stubs marked +/-
PRESSURE situated on the left side of the front panel are used to measure pressure. Negative pressure in
flue gas channel (chimney draught) can be measured with the one stub only; differential pressure
measurement is possible using both stubs. The measuring range of the pressure sensor is +/-50 hPa.
.2.6 Analogue inputs
The analogue inputs installed can be used to measure voltage or current on one channel, temperature using
thermocouples and temperature using thermistors. The values measured can be viewed on the screen or
stored in the EEPROM memory.
Tables 2 and 3 show the technical data for the analogue inputs.
Parameter U1 I1
Range -10 V ¸10 V -10 mA ¸10 mA
Input resistance 100 k### 100 ###
Resolution 10 mV 10 µA
Tab. 2 Parameters for current and voltage channels
Parameter Thermocouple Thermistor
Range Ni-CrNi: 0 ¸1300 °C
Pt-RhPt: 0 ¸1600 °C
Fe-CuNi: 0 ¸700 °C
Pt 100: 0 ¸200 °C
Pt 500: 0 ¸100 °C
Resolution 1 °C 1 °C
Tab. 3 Parameters for temperature channels

CONSTRUCTION Sensonic 4000
The analogue inputs are connected to the sockets U/I1, TEMP1 on the front of the analyser. Table 4 shows
the use of the pins in the sockets (seen from the socket side).
2 3
1
Picture 2 Socket for analogue inputs
10